Exhaust Rear Muffler Replacement (without 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 .
2. |
Remove the 2 exhaust rear
muffler hanger insulators (3) from the exhaust rear muffler
(4). |
3. |
Remove the exhaust rear
muffler end pipe bracket bolt (1) from the exhaust rear muffler end
pipe bracket (2) |
4. |
Remove the exhaust rear
muffler end pipe bracket (2). |
5. |
Place the exhaust system onto
the rear axle. |
6. |
Note the dent marks (1) around
the exhaust pipe, if available. |
7. |
If no markings are available,
measure and mark the cut position as shown in the graphic.
|
|
Note: Use a suitable
flat steel bar (2) or equivalent tool to measure the cut position I
and II with a rule (1).
|
|
Note: A second
technician is required.
|
|
• |
Cut position for 1.4L LDD; I=
143 mm; II= 142 mm |
|
• |
Cut position for 1.4L LUJ; I=
141 mm; II= 145 mm |
|
• |
Cut position for 1.6L LDE; I=
140 mm; II= 144 mm |
|
• |
Cut position for 1.3L Diesel;
I= 139 mm; II= 144 mm |
|
• |
Cut position for 1.7L Diesel;
I= 140 mm; II= 147 mm |
|
• |
Cut position for 2.0L Diesel;
I= 142 mm; II= 149 mm |
8. |
Support the intermediate
pipe. |
9. |
Cut the exhaust rear silencer
(4) with CH-6614 cutter (2) at the marked position
(3). |
10. |
Remove the exhaust rear
muffler end pipe. |
11. |
Cut the exhaust rear muffler
(4) at the marked position (1). |
12. |
Remove the exhaust rear
muffler. |
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. |
|
Note: A second
technician is required.
|
2. |
Install the exhaust rear
muffler (6) at the 2 exhaust rear muffler hanger insulators
(5). |
3. |
Install the exhaust pipe clamp
(1) and loosely tighten. |
4. |
Install the exhaust rear
muffler end pipe. |
5. |
Install the exhaust rear
muffler end pipe bracket (3) to the exhaust rear muffler end
pipe. |
6. |
Install the exhaust rear
muffler end pipe bracket bolt (4) to the exhaust rear muffler end
pipe bracket (3) and tighten to 22 N·m (16 lb
ft) . |
7. |
Install the exhaust pipe clamp
(2) and loosely tighten. |
8. |
Position the exhaust rear
muffler. |
9. |
Tighten the exhaust pipe
clamps (1) to 30 N·m (22 lb ft) .
|
10. |
Position the exhaust rear
muffler end pipe. |
11. |
Tighten the exhaust pipe clamp
(2) to 30 N·m (22 lb ft) . |
|