Parts and materials for repair
Parts that must be replaced:
- exhaust pipe coupling (if she is),
- gasket or o-ring connecting the catalytic converter or pre-catalytic converter to the rest of the exhaust pipe,
- exhaust pipe clamp or clamps (if they are).
Materials:
- sealant for the exhaust system,
- surface cleaner,
- matting circles in grey.
Instructions to be followed
Important note. Inside the catalytic converters are ceramic fibers; they are enclosed in a closed container from which they cannot spill out. Do not make holes or cut catalytic converters.
1. When removing and installing a catalytic converter or pre-catalytic converter, they must not be subjected to mechanical shocks that could lead to their destruction.
2. The exhaust system is completely made of stainless steel.
3. Make sure that the flange connection of the catalytic converter or pre-catalytic converter to the rest of the exhaust pipe is perfectly tight.
For this:
- clean the mating surfaces of the joint using gray matting discs,
- degrease the mating surfaces of the connection with a surface cleaner and a clean rag,
- be sure to replace the gasket or o-ring of the joint.
One-piece Exhaust Piping Features
Cutting a one-piece exhaust pipe
The exhaust pipes are made in one piece.
To replace individual parts of the exhaust pipeline, it is necessary to cut it.
For this you need:
- clearly define the cutting area as explained below,
- use the cutting tool correctly (Mot. 1199-01),
- correctly install the exhaust pipe coupling.
Designation of the cutting zone of the exhaust pipeline
The cutting zone is marked with two marks on the outlet pipeline.
Cut zone example
Before cutting the exhaust pipe, mark the middle (D) between two marks (P1) And (R2).
The distance between two marks on the exhaust pipe is (X1): 80 mm.
Using tool Mot. 1199-01
Install fixture (Mot. 1199-01) (1) to the exhaust pipe.
Tighten the two screws until the tool is in contact with the pipe, so that the cutter is pressed lightly against the pipe.
Turn the cutter with the handle while pressing it against the pipe (as shown in the picture above).
Tighten both attachment screws as you proceed until the cut is complete.
Note: To avoid deformation of the pipe, do not overtighten the fixture screws.
After cutting the pipe, file off the burrs on the part of the exhaust pipe that will be reused on the vehicle.
Installing the outlet pipe coupling
Attention! The old exhaust pipe coupling cannot be reused.
Exhaust pipe coupling with 1 bolt
Exhaust pipe coupling with 2 bolts
Put the coupling on the part of the exhaust pipe installed on the car.
Align the exhaust pipe until it contacts the tabs (2) inside the repair sleeve.
Slightly tighten the pinch bolt or exhaust pipe coupling bolts (depending on the model).
Install the second part of the exhaust pipe on the vehicle by inserting it into the exhaust pipe coupling.
Note: If necessary, use a hydraulic jack to lift and hold heavy and bulky parts of the exhaust piping.
Insert the second part of the exhaust pipe until it comes into contact with the protrusions inside the exhaust pipe coupling.
Check the alignment of the cutting zone marks (3) (if they are).
Orient the coupling so that its pinch bolt or bolts do not come into contact with the heat shields.
Torque tighten:
- exhaust pipe coupling nut with one pinch bolt (25 Nm) (if she is),
- exhaust pipe coupling nuts with two pinch bolts (18 Nm) (if she is).
Check and correct if necessary:
- lack of contact under the body of the exhaust pipeline with heat shields,
- the presence and reliability of fastening of all thermal screens.
Note: A damaged heat shield must be replaced.
Start the engine.
Check for leaks, repair if necessary.
Note: In the event of a gas leak from the exhaust pipe fitting A with 1 tie bolt, apply exhaust system sealant to the fitting.
If the leak cannot be repaired with sealant:
- remove and replace the used exhaust pipe coupling,
- check the condition of the exhaust pipes (condition of pipe surfaces, presence of burrs in the cutting zone, pipe deformation),
- reinstall the exhaust pipe coupling following the instructions above.