Petrol engine 2.0 l
System of release of the fulfilled gases. Engine 2.0 l ALT
- 1 - Pre-silencer. In the original version, together with an additional silencer. Can be replaced separately in case of repair
- 2 — Bolt*, 25Nm. Be sure to replace
- 3/4 - Suspension
- 5 - Bolt, 25Nm
- 6 - Nut *, 30nm
- 7 - Sealing gasket *
- 8 - Exhaust manifold
- 9 - Catalytic converter. Don't drop
- 10 - Precatalytic lambda probe 1, 55Nm
- 11 - Postcatalytic lambda probe 2, 55Nm
Note: Lubricate only the threads of both sensors with high-temperature paste G 052 112 A3. The paste must not get into the groove of the sensor housing.
- 12 - Sealing gasket *
- 13 - Downpipe of the exhaust system with a connecting element. Do not tilt the element more than 10°
- 14 - Suspension
- 15 - Terminal sleeve
- 16 - Nut, 40Nm
- 17 - Clamp, 25Nm
- 18 - Tip
- 19 - Suspension
- 20 - Nut, 25Nm
- 21 - Additional muffler. In the original version, together with a preliminary silencer. Can be replaced separately in case of repair
- 22 - Terminal sleeve
- 23 - Nut, 40Nm
- 24 - Bolt, 25Nm
- 25 - Suspension
*) Be sure to replace.
Caution: Elements of the exhaust system can be replaced individually. In the original equipment, the pre-muffler and after-muffler form a single unit. The center and secondary mufflers can be separated from each other during repair and are sold separately as spare parts.
The operation of lifting and placing the vehicle on stands is dangerous! Therefore, before carrying out the operation, read Section Jacking and towing.
1. Raise and place the car on stands, remove the bottom cover of the engine, refer to Section Removal and installation of the upper engine cover / lower protection of the engine compartment / subframe.
2. Spray all bolts and nuts of the exhaust system with a rust-dissolving agent and wait a while.
3. Turn out bolts on a connecting flange catalytic converter/receiving pipe.
Caution: If the exhaust system must be removed together with the catalytic converter, unscrew the mounting bolts on the exhaust manifold / catalytic converter flange and remove the lambda probes, refer to Section Removal and installation of the catalytic converter and lambda probes.
4. Disconnect the front cross member of the exhaust system mounting.
Caution: Do not bend the flexible connector more than 10°in the receiver, otherwise it may be damaged. With the help of an assistant, disconnect and remove the exhaust system from the clamps.
Diesel engine 2.5L
Removal of preliminary and additional mufflers
System of release of the fulfilled gases. Diesel engine 2.5L
- 1 - Bolt, 23Nm
- 2 - Suspension. When installing, the arrow must point in the direction of travel of the vehicle
- 3 - Central muffler. In the original equipment of the car, the assembly is together with an additional muffler. Can be replaced separately in case of repair
- 4 - Muffler pre-pipe with two catalytic converters, with a connecting element. Do not bend the element more than 10°
- 5 - Sealing gasket *
- 6 - Preliminary catalytic converter
- 7 - Nut, 25Nm
- 8 - Turbocharger
- 9 - Nut, 25Nm
- 10 - Terminal sleeve front
- 11 - Nut, 40Nm
- 12 - Additional muffler. In the original version, together with the central muffler. Can be replaced separately in case of repair
- 13 - Suspension
- 14 - Bolt, 23Nm
- 15 - Additional muffler. In the original version, together with the central muffler. Can be replaced separately in case of repair
- 16 - Nut, 23Nm
- 17 - Nut, 40Nm
- 18 - Rear terminal sleeve. Before fixing, align the exhaust system so that it is in position. Bolted connections must face to the right
*) be sure to replace.
If the front and rear silencers have not yet been replaced, they must be cut at certain points to replace them separately. The separation point is marked by small depressions on the muffler pipe.
1. Cut the pipe with a hacksaw according to the marks. The side marks show how far the terminal sleeve can be moved.
2. Disconnect the muffler from the rubber holders and remove.
Installing the exhaust system
Warning: Gaskets, nuts and bolts must always be replaced. To facilitate later disassembly of the exhaust system, it is recommended to lubricate the fastening bolts and nuts with a high-temperature paste, for example, Liqui Moly LM-508-ASC.
Caution: Do not bend the downpipe flexible connector more than 10°, otherwise it may be damaged.
1. Install the exhaust system with the help of an assistant in the rubber holders.
2. Torque the front cross member 25Nm on the bottom of the car.
3. Secure the exhaust system to the flange with a new O-ring, new bolts and nuts. Observe tightening torques.
4. If lambda probes were filmed, install them, refer to Section Removal and installation of the catalytic converter and lambda probes.
Installation of preliminary and additional mufflers
If the preliminary or additional silencers were only removed, secure the silencers with new clamps.
1. Position the terminal sleeve (1) in the middle of the cut. Terminal sleeve (1) must be horizontal, the bolts must point to the left.
2. Install the terminal sleeve so that the end of the bolt does not protrude beyond its lower edge.
3. Tighten the bolts evenly to the torque 40Nm.
4. Expose the exhaust system so that it is located freely, without stress or deformation.
5. Replace the engine bottom cover.
End tube replacement
1. Cut off the end pipe with a hacksaw (1) at the point of separation (WITH).
2. Slide the end pipe (3) up to the mark (A). At the same time, align the slot on the end pipe with the mark (IN). Tighten the clamp (2) moment 25Nm.
3. Expose the end tube.
Checking the exhaust system for leaks
On vehicles with a variable catalytic converter, a leak in the exhaust system can lead to difficulty starting the engine. Engine stops, shakes when idling, twitches as rpm increases.
1. Start the engine and, with the engine running, cover the exhaust system with a rag.
2. Listen to the exhaust system. If necessary, spray the cylinder head/exhaust manifold and exhaust manifold/downpipe connections with a leak detector. Check for bubbles.
3. Repair the leak.
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