General information
1. Depending on the model, the exhaust system consists of two or three sections. The two-section system consists of a suction pipe and a rear pipe. The three-section system consists of a front pipe, an intermediate pipe and a rear pipe. The three-piece system also has a catalytic converter that is integrated with the downpipe and intermediate pipe.
2. Sections of the exhaust system are connected or using clamps with spring-loaded balls (which allows some mobility of the exhaust system), or with a clamping ring.
3. The entire length of the system is suspended by rubber mounts.
4. Each section can be removed individually or, alternatively, the entire system can be removed. Even if only one part of the system needs attention, it is often easier to remove the entire system and separate the sections on a workbench.
5. To remove the system or part of the system, first raise the front or rear of the vehicle and securely support it under it (see «Lifting and placing the car on supports»). Alternatively, park the vehicle over a pit or raise it onto a flyover.
Downpipe
6. On models with a 1.9L engine and early models with a 2.0L engine, unscrew the nuts on the flange connection between the exhaust pipe and the manifold and remove the spring caps and springs. Turn out bolts and remove a laying from a wire grid. On late models with a 2.0L engine, unscrew the nut, remove the washer and remove the bolt in the bolted connection on the clamp ring and remove the clamp ring from the turbocharger flange connection.
7. Have an assistant support the front end of the pipe, and then remove the nut, remove the washer, and remove the bolt in the bolted connection on the clamp ring and remove the clamp ring from the flange connection.
8. Release the pipe from the rubber support (supports) and remove it from under the car.
Intermediate pipe
9. Remove the nuts, washers and bolts in the bolted connections on both clamp rings and remove both clamp rings from the flange connections.
10. Release a pipe from a rubber support and remove it from under the car.
Rear pipe
11. Loosen the nut, remove the washer and remove the bolt in the bolted connection on the clamp ring and remove the clamp ring from the flange connection.
12. Release a back pipe from the corresponding rubber support and remove it from the car.
Complete system
13. Separate the downpipe from the manifold/turbocharger as described above.
14. Call an assistant, release the system from all rubber supports and remove it from under the car. Remove the wire mesh pad from the manifold joint (if applicable).
Heat shield (-s)
15. The heat shields are attached to the underside of the vehicle with various nuts and bolts. If the screen is removed to gain access to the elements located behind it, unscrew the nuts and / or remove the clamps (to do this, unscrew the central screw, and then remove the entire retainer) and then remove the screen. On some models, to be able to remove the large heat shield, it may be necessary to release the exhaust system from its supports.
Installation
16. Each section is installed in the reverse order of removal, taking into account the following points:
- A) Remove all traces of corrosion from the flanges and replace any necessary gaskets.
- b) Inspect rubber mounts for signs of damage or deterioration and replace if necessary.
- V) If a clamp ring is used in the joint, apply exhaust system assembly paste to the flange joint to ensure a gas-tight joint.
- G) Before tightening the exhaust system bolts/nuts, make sure that all rubber mounts are properly positioned and that there is sufficient clearance between the exhaust system and the bottom of the vehicle.