Installing exhaust system

Installing the complete exhaust system

CAUTION: Component with heavy weight.
Injury hazard!

Note component's center of gravity.
Support component using a jack.
Secure component against falling off the jack.

CAUTION: Heavy component.
Heavy components can lead to injury or damage.

Remove and install heavy components with the aid of another person/other persons.

CAUTION: Grinding dust from grinding of components.
Hazardous to health!

Directly draw off the grinding dust.
Ensure adequate ventilation.
Conduct all work in appropriate personal protective equipment only.

NOTE: TECHNICAL INFORMATION
Check the exhaust system for tightness after installation.

NOTE: TECHNICAL INFORMATION
Mount the exhaust system in a de-energized state, following the tightening sequence from the rear silencer towards the exhaust manifold.

CAUTION: Shavings resulting from sawing or grinding components.
Injury hazard!

Conduct all work in appropriate personal protective equipment only.
Wear safety goggles and hand protection.

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Version with ribbon clamp:
Open the weld seam (1) with a conventional tool.
Remove ribbon clamp (2).
Replace the (2) ribbon clamp.
Parts: Ribbon cable clamp

NOTE: Schematic diagram is for example purposes. Some parts may differ in certain details.

Check all rubber mounts (1) of the exhaust system for damage and replace, if necessary.

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NOTE: TECHNICAL INFORMATION
Conduct the following operation with the assistance of a second person.

Insert and install the exhaust system with the help of another person.
Replace nuts (1).
Parts: Nuts
Tighten nuts (1).

TIGHTENING TORQUES SPECIFICATION

Rear silencer to body/bumper support
M8 Replace nuts.	Tightening torque 19 Nm

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Replace nuts (2).
Parts: Nuts
Tighten nuts (2).

TIGHTENING TORQUES SPECIFICATION

Rear silencer to body/bumper support
M8 Replace nuts.	Tightening torque 19 Nm

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Connect and lock the connector (1).
The connector (1) must engage audibly.

NOTE: The following step(s) must be performed if the listed component(s) is/are installed.
Replace the screw (1).
Parts: Screw
Tighten the bolt (1) on the rear axle support.

TIGHTENING TORQUES SPECIFICATION

Exhaust system to rear axle carrier
M8x25 Replace screw.	tightening torque 28 Nm

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NOTE: The following step(s) must be performed if the listed component(s) is/are installed.

Replace the screw (3).
Parts: Screw
Tighten the screw (3) on the rear axle support.

TIGHTENING TORQUES SPECIFICATION

Exhaust system to rear axle carrier
M8x25 Replace screw.	tightening torque 28 Nm

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Mount the ground strap (2) and tighten the screw (1).
Replace nut (1).
Parts: Nut
Tighten nut (1).

TIGHTENING TORQUES SPECIFICATION

Front pipe/front silencer/gasoline particulate filter to the transmission holder
M8 Replace nut.	tightening torque 19 Nm

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Tighten the ribbon clamp (1).

TIGHTENING TORQUES SPECIFICATION

Exhaust system to catalytic converter
Ribbon clamp nut M8 Replace the ribbon clamp.	tightening torque 26 Nm
Ribbon clamp nut M10 Replace the ribbon clamp.	tightening torque 55 Nm

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Version with V ribbon clip:
Replace V-band clamp.

Parts: V-band clamp

Unscrew the nut (1) and remove the sealing ring (2).

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Bend all sheet metal tabs around their entire perimeter (apart from those in the marked areas) with a suitable tool.

Bend all sheet metal tabs around their entire perimeter (apart from those in the marked areas) with a suitable tool.

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Mount the V-clip (1) on the sealing ring (2).
Make sure that the V-ribbon clip is (1) correctly positioned on the sealing ring (2).

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Make sure that, after mounting, the V-ribbon clip is on the sheet metal tabs in the marked areas.

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Connect the exhaust system (1) with the catalytic converter (2) and position it correctly (arrow).

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Make sure that V-clip (1) is fitted correctly.
Tighten down screw (2).

TIGHTENING TORQUES SPECIFICATION

V-ribbon clip to catalytic converter
V-ribbon clip Replace V-ribbon clip.	tightening torque 25 Nm

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If installed: Install the torsion strut on the right, and on the left where required

Install right torsion strut

NOTE: Description is for left component only. Procedure on the right side is identical.

Thread in torsion strut (2) and install.
Replace screws (1).
Parts: screw
Tighten down screws (1).

TIGHTENING TORQUES SPECIFICATION

Torsion strut to mounting
M12 Replace screws.	Tightening torque 100 Nm Angle of rotation 90°

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NOTE: Description is for left component only. Procedure on the right side is identical.

Thread in the tank cover (1) and install.
Tighten screws (arrows).

TIGHTENING TORQUES SPECIFICATION

Undershield
screw	Tightening torque 2.6 Nm
Plastic nut	Tightening torque 2.6 Nm

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For dual-flow exhaust system: Install the left torsion strut

Thread in torsion strut (2) and install.
Replace screws (1).
Parts: screw
Tighten the screws (1).

TIGHTENING TORQUES SPECIFICATION

Torsion strut to mounting
M12 Replace screws.	Tightening torque 100 Nm Angle of rotation 90°

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Thread in the tank cover (1) and install.
Tighten screws (arrows).

TIGHTENING TORQUES SPECIFICATION

Undershield
screw	Tightening torque 2.6 Nm
Plastic nut	Tightening torque 2.6 Nm

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Install the connecting supports on the tunnel

Version A:

Install the connecting support (2) on the tunnel.

Tighten screws (arrows).

Tighten down screws (1).

TIGHTENING TORQUES SPECIFICATION

Connecting support to tunnel
M8x25 screw	tightening torque 20 Nm
Screw	tightening torque 3 Nm

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Version B:

Install the connecting support (2) on the tunnel.

Tighten screws (arrows).

Tighten down screws (1).

TIGHTENING TORQUES SPECIFICATION

Connecting support to tunnel
M8x25 screw	tightening torque 20 Nm
Screw	tightening torque 3 Nm

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