17.1a. Muffler installation details for models with 3.0L 1st generation engines:
1 - Bolt, subject to replacement, 23 Nm;
2, 21, 26 - Support with rubber suspension;
3 - Double clamp;
4 - Nut, 23 Nm;
5, 12, 18, 20, 22, 27 - Bolt, 23 Nm;
6 - Bracket;
7 - Turbocharger;
8, 14 - Gasket, subject to replacement;
9* - Nut, subject to replacement, 23 Nm;
10 - Lambda probe "G39", 50 Nm;
11 - Primary catalytic converter with flexible section;
13 - Nut, subject to replacement, 23 Nm;
15 - Sensor "G506" temperature before the particulate filter or sensor No. 3 "G495" temperature before the particulate filter;
16 - Diesel particulate filter;
17, 19 - Support;
23, 25 - Left exhaust pipe, 60 Nm;
24 - Rear muffler.
17.1b. Installation details of catalytic converters and diesel particulate filters for models with 3.0L SCR engines (SATA, CCMA and CLZB):
1, 10, 16, 20, 22, 25 - Bolt, 23 Nm;
2, 24 - Support with rubber suspension;
3 - SCR catalytic converter;
4 - Clamp;
5, 8, 9, 13 - Gasket, subject to replacement;
6 - Nozzle "N474" for injection of liquid "AdBlue";
7 - Bolt, must be replaced;
11 - Converter bracket 15;
12, 17, 23 - Nut*, subject to replacement, 23 Nm;
14 - Turbocharger;
15 - Primary catalytic converter with flexible section;
18 - Diesel particulate filter with catalytic converter and line of sensor No. 1 "G450" exhaust pressure;
19, 21 - Support;
26 - Nut, 23 Nm;
27 - Double clamp.
17.1c. Installation details for the catalytic rear muffler and exhaust pipes for models with 3.0L SCR engines (SATA, CCMA and CLZB):
1, 10 - Exhaust pipe;
2, 11 - Bolt, 60 Nm;
3, 7, 8 - Support with rubber suspension;
4, 6, 9 - Bolt, 23 Nm;
5 - Rear muffler, there are options for different standards (EU6 and BIN5).
17.1d. Muffler installation details for models with 3.0L 2nd generation engines (except CLZB):
1 - Exhaust pipe;
2 - Bolt. 60 Nm;
3, 6, 8, 14, 19, 23 - Bolt, 23 Nm;
4, 7 - Support with rubber suspension;
5 - Rear muffler;
9 - Converter bracket 13;
10 - Turbocharger;
11, 16 - Gasket, subject to replacement;
12* - Nut, subject to replacement, 23 Nm;
13 - Primary catalytic converter with flexible section;
15 - Nut, subject to replacement, 23 Nm;
17 - Diesel particulate filter;
18, 22 - Support;
20 - Double clamp;
21 - Nut, 23 Nm.
17.1e. Diesel particulate filters and catalytic converters for models with 4.2L engines:
1, 18, 20, 22 - Bolt, 23 Nm;
2, 17 - Support with suspension;
3 - Right particulate filter;
4, 8, 15 - Gasket, subject to replacement;
5, 14 - Nut, subject to replacement, 23 Nm;
6 - Right catalytic converter with flexible section;
7 - Right turbocharger;
9, 12 - Nut*, subject to replacement, 23 Nm;
10 - Left turbocharger;
13 - Right catalytic converter with flexible section;
16 - Left particulate filter;
19, 21 - Support.
17.1f. Diesel particulate filters and catalytic converters for models with 4.2L engines:
1, 20 - Bolt, 60 Nm;
2 - Right exhaust pipe;
3, 7, 13, 21 - Bolt, 23 Nm;
4, 6, 12,1 8 - Support with suspension;
5 - Intermediate pipes;
8, 11, 15, 17 - Nut, 23 Nm;
9, 10, 14, 16 - Double clamp;
19 - Left exhaust pipe;
22 - Rear muffler; it is normally installed assembled with intermediate pipes, however, these parts can be replaced separately by cutting them and connecting them with a clamp.
High temperature grease should also be applied to the threads of parts marked with "*". Flexible sections of exhaust system parts must not be bent at an angle greater than 10°.
2. The exhaust system clamp bolts must be located at the bottom. The exhaust system should be adjusted without tension after the pipes have cooled down. To properly align the exhaust system, push it forward (arrow in the illustrations), so that the rubber lower mounting points of the rubber hangers are at a distance (a) from the suspension axis, and then in this position, evenly tighten the clamp bolts with a torque of 23 Nm.
17.2a. Preload on the front left rubber suspension (a = 4 mm).
17.2b. Preload on the front right rubber mount of 4.2 L engines (a = 2 mm).
17.2 sec. Preload on rear rubber suspensions (a = 10 mm).
Rear mufflers should be positioned so that the distances between each pipe and the bumper are equal on all sides of the pipe.
3. The details of the exhaust manifold installation are shown in the illustrations.
17.3a. Installation details of exhaust manifolds for models with 3.0L 1st generation engines and 3.0L SCR engines (SATA, SSMA) using the left side as an example, with an intermediate pipe:
1* - Nut, subject to replacement, 25 Nm;
2 - Exhaust manifold, there are options: sheet metal or cast;
3, 4, 8 - Gasket, subject to replacement;
5* - Bolt, subject to replacement, 30 Nm, then tighten to an angle of 90°;
6 - Intermediate tube; it is attached to a sheet metal manifold with bolts (9) and nuts (7), and to a cast manifold it is attached with bolts (7), since the manifold has a thread;
7 - Bolt* or nut, to be replaced, 10 Nm, then 30 Nm, then tighten to an angle of 90°;
9* - Bolt, subject to replacement.
17.3b. Installation details of exhaust manifolds for models with 3.0L 2nd generation engines, using the left side as an example:
1* - Nut, subject to replacement, 25 Nm;
2 - Exhaust manifold, there are options: sheet metal or cast;
3, 4 - Gasket, subject to replacement;
5* - Bolt, subject to replacement, 30 Nm, then tighten to an angle of 90°.
17.3s. Installation details for the left exhaust manifold of 4.2L models with a BTR engine:
1* - Nut, to be replaced, 25 Nm, then tighten to an angle of 180°;
2.8 - Gaskets, subject to replacement;
3 - Cylinder head;
4 - Bolt, 10 Nm;
5 - Heat shield;
6* - Bolt, 20 Nm, then tighten to an angle of 90°;
7 - Exhaust manifold;
9 - Turbocharger.
17.3d. Installation details of the left exhaust manifold for 4.2L models with CCFA/CCFC engines:
1* - Nut, to be replaced, 25 Nm, then tighten to an angle of 180°;
2 - Plate;
3 - Exhaust manifold;
4, 7 - Gaskets, subject to replacement;
5 - Cylinder head;
6* - Bolt, 20 Nm, then tighten to an angle of 90°;
8 - Turbocharger.
High temperature grease should also be applied to the threads of parts marked with "*".
4. The installation locations of the lambda probes and exhaust gas temperature/pressure sensors are shown in the illustrations.
17.4a. Locations for installing lambda probes and exhaust gas temperature/pressure sensors for models with 3.0 l 1st generation engines:
1 - Lambda probe "G39", 50 Nm;
2* - Nut, 25 Nm;
3 - Turbocharger;
4* - Sensor No. 1 "G235" exhaust gas temperature, 45 Nm;
5 - Sensor No. 1 "G450" exhaust gas pressure, 45 Nm: on BUG/BUN engines - with two tubes, and on CASA/CASB engines - with one tube;
6* - Sensor (45 Nm): on BUG/BUN engines - sensor "G506" of temperature before the particulate filter, and on "G495" engines - sensor No. 3 "G495" of exhaust gas temperature;
7 - Diesel particulate filter.
17.4b. Locations for installing lambda probes and exhaust gas temperature/pressure sensors for models with 3.0 l SCR engines (SATA, SSMA):
1 - SCR catalytic converter;
2* - Sensor No. 4 "G648" exhaust gas temperature, 45 Nm;
3 - Diesel particulate filter;
4 - Primary catalytic converter;
5* - Sensor No. 3 "G495" exhaust gas temperature, 45 Nm;
6* - Sensor No. 1 "G20" catalytic converter temperature (only on engines of the BIN5 standard: SATA), 45 Nm;
7* - Sensor No. 2 "G448" exhaust gas temperature (only on engines of the BIN5 standard: SATA), 45 Nm;
8* - Nut, 2.5 Nm;
9 - NOx concentration sensor "G295";
10 - Lambda probe "G39" with heating element "Z19", 50 Nm;
11 - Turbocharger;
12* - Sensor No. 1 "G235" exhaust gas temperature, 45 Nm;
13 - Sensor "G505" of the pressure difference with two tubes, or sensor No. 1 "G450" of the EGR pressure;
14, 17 - Nut, 3.5 Nm;
15 - Pressure lines for sensor 13, 45 or 23 Nm;
16 - Sensor No. 2 "G687" NOx concentration.
17.4 sec. Installation locations of lambda probes and exhaust gas temperature/pressure sensors for models with a 3.0 l SCR (CLZB) engine:
1, 14 - Nut, 3.5 Nm;
2 - Sensor No. 2 "G687" NOx concentration;
3 - SCR catalytic converter;
4* - Sensor No. 4 "G648" exhaust gas temperature, 45 Nm;
5 - Diesel particulate filter;
6 - Primary catalytic converter;
7* - Sensor No. 3 "G495" exhaust gas temperature, 45 Nm;
8 - Nut, 2.5 Nm;
9 - NOx concentration sensor "G295";
10 - Lambda probe "G39" with heating element "Z19", 50 Nm;
11 - Turbocharger;
12* - Sensor No. 1 "G235" exhaust gas temperature, 45 Nm;
13 - Sensor "G505" of the pressure difference with two tubes, or sensor No. 1 "G450" of the EGR pressure;
15 - Pressure line for sensor 13, 45 or 23 Nm.
17.4d. Installation locations of lambda probes and exhaust gas temperature/pressure sensors for models with 3.0 l 2nd generation engines (except CLZB):
1 - Lambda probe "G39" with heating element "Z19", 50 Nm;
2* - Sensor No. 1 "G235" exhaust gas temperature, 45 Nm;
3 - Differential pressure sensor "G505" (only on CJGA/CJGC and CJMA engines);
4* - Sensor No. 3 "G495" exhaust gas temperature, 45 Nm.
17.4e. Installation locations of lambda probes and exhaust gas temperature/pressure sensors for models with 4.2 L engines:
1 - Diesel particulate filter for the left bank of cylinders;
2 - Pressure line for sensor 5, 23 Nm;
3, 17 - Bolt, 9 Nm;
4 - Sensor No. 2 "G498" temperature before the particulate filter;
5 - Sensor No. 2 "G524" differential pressure, 45 Nm;
6, 13 - Nut, 4.5 Nm;
7 - Lambda probe No. 2 "G108" with heating element No. 2 "Z28", 55 Nm;
8 - Sensor No. 1 "G236" exhaust gas temperature for the left bank of cylinders, 45 Nm;
9/10 - Turbocharger for left/right bank of cylinders;
11* - Sensor No. 1 "G235" exhaust gas temperature, 45 Nm;
12 - Lambda probe "G39" with heating element "Z19", 55 Nm;
14 - Differential pressure sensor "G505";
15 - Temperature sensor "G506" before the diesel particulate filter, 45 Nm;
16 - Pressure line for sensor 14, 23 Nm;
18 - Diesel particulate filter for the right bank of cylinders.
The threads of the new lambda probes already have the necessary lubricant applied. Before installing used lambda probes, clean their threads and lubricate them with high-temperature grease, avoiding any contact with the grooves in the lambda probe housing. High-temperature grease should also be applied to the threads of parts marked with an "*".
(The original source of the article can be found on the website Audimanual.ru)