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Exhaust System Replacement - 1.4L LDD, LUH, and LUJ > < Exhaust Manifold Heat Shield Replacement - 1.6L LGE and LLU

Astra J

Exhaust Rear Auxiliary Muffler Replacement (1.6L LLU)

Special Tools

CH-6614   Chain-Type Pipe Cutter

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning:  Refer to Exhaust Service Warning .

Warning:  Refer to Protective Goggles and Glove Warning .

Caution: Refer to Exhaust Flexible Pipe Bending Caution .

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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2. Remove the 2 exhaust rear muffler hanger insulators (3) from the exhaust rear muffler (4).
3. Remove the 2 auxiliary exhaust rear muffler bracket bolts (1) from the auxiliary exhaust rear muffler brackets (2).
4. Remove the 2 auxiliary exhaust rear muffler brackets (2) from the auxiliary exhaust rear muffler (5).
5. Place the exhaust system onto the rear axle.

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6. Note the dent marks (1) around the exhaust pipe if available.

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Note:  Use a suitable flat steel bar (2) or equivalent tool to measure the cut position II with a rule (1).

Note:  A second technician is required.
7. If no markings are available, measure and mark the cut position II as shown in the graphic.
  Cut position II= 145 mm

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8. Cut the auxiliary rear silencer (3) with CH-6614   cutter (2) at the marked position (1).
9. Remove the auxiliary exhaust rear muffler (3).

Installation Procedure

1. In case of reuse of the exhaust parts, check the exhaust pipes at the separating sets for the following conditions:
  •  Roundness of the exhaust pipe, any deformation in the area of the double-clamp must be eliminated.
  •  Burrs inside and outside the exhaust pipe at the cutting edge, use a rasp to eliminate.
  •  Rust at the exhaust pipe outside, use sandpaper to eliminate.

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Note:  A second technician is required.
2. Install the exhaust rear muffler (6) to the 2 exhaust rear muffler hanger insulators (5).
3. Install the exhaust pipe clamp (1) and loosely tighten.
4. Install the 2 auxiliary exhaust rear muffler brackets (2) to the auxiliary exhaust rear muffler (4).
5. Install the auxiliary exhaust rear muffler (4).

Caution: Refer to Fastener Caution .
6. Install the 2 auxiliary exhaust rear muffler bracket bolts (3) to the auxiliary exhaust rear muffler brackets (2) and tighten to 22 N·m (16 lb ft) .
7. Position the auxiliary exhaust rear muffler (4).
8. Install the exhaust pipe clamp (1) and loosely tighten.
9. Tighten the exhaust pipe clamp (1) to 20 N·m (15 lb ft) .
10. Lower the vehicle.

Exhaust System Replacement - 1.4L LDD, LUH, and LUJ > < Exhaust Manifold Heat Shield Replacement - 1.6L LGE and LLU