Attention!
- - The area from the exhaust manifold up to and including the converter must be airtight.
- - All removed gaskets must be replaced without fail (especially the converter flange gasket).
- - When removing and installing the converter, protect it from impacts that could damage it.
Removing
1. Elements of the exhaust system are suspended on the bottom of the body using rubber-metal cushions 1. As a rule, «can be detached without the use of a tool, manually by lifting the exhaust pipe. However, in some cases, it is necessary to unscrew the bolts securing the bracket 2 to make it easier to remove the suspension cushions.
2. The exhaust system pipeline is a non-separable unit, i.e. there are no pipe joints from the inlet to the catalytic converter or front muffler to the outlet of the main muffler. In this regard, it is necessary to cut the exhaust system pipeline to replace one of the pipeline elements during maintenance exhaust gases.
For this you need:
- accurately determine the cutting zone;
- use cutting tool Mot. 1199-01;
- install repair sleeve.
3. The cutting zone is marked with two blows of the core on the exhaust pipe.
Maximum (depending on engine type) There are two cutting zones on the exhaust pipe, which are between the converter and the resonator and between the resonator and the main muffler. The distance between these two marks is 90 mm. To cut the pipe, it is necessary to draw a line D in the middle between these marks (R1 and R2).
Attention! To cut exhaust pipes, you must have tool Mot. 1199-01; This tool allows you to cut pipes with a wall thickness of up to 2 mm.
Installation
1. In order to avoid exhaust gas leakage, it is very important to correctly install the coupling on the exhaust pipes, i.e. the pipe must go inside the coupling until it stops against the internal protrusions.
Note. Couplings are available in two diameters:
- 50 mm;
- 45 mm.
Start by installing the coupling on the used part of the pipe, then adjust the diameter of the coupling hole by carefully tightening it.
2. Check the position of the pipe against the stops.
3. Install the new pipe section.
4. Before installing the coupling on the pipe, mastic can be applied to the inner surface of the coupling to prevent exhaust gas leakage.
(Mastic for exhaust systems, catalog number: 77 01 421 161 SODICAM).
Attention! The bolt and nut used to fasten the coupling must be oriented strictly vertically to avoid contact with the bottom of the body. The installed clutch cannot be reused.
5. The coupling nut has a groove A, which serves to determine the correct tightening torque. During tightening, when the groove is compressed, a characteristic sound is heard, which indicates that the nut is tightened with a torque of 25 Nm.
Attention! Make sure:
- - that the exhaust system pipeline does not come into contact with the bottom of the body anywhere;
- - in the presence and reliable fastening of all heat-reflecting shields of the exhaust system;
- - that both cut zone marks are exactly aligned.
Pic. 2.129. Exhaust system piping and cutting zone locations:
1 - Front muffler;
2 - Main muffler;
3 - Catalytic converter;
ZC - Pipe cutting zone.