18 00 020 Remove & install complete exhaust system

Special tools required:

31 2 220

WARNING: Danger of burning and other injuries!
Only perform this repair after the exhaust system has cooled down.
Removal of the exhaust system must be carried out with the assistance of a second person .

CAUTION: Handle the exhaust system carefully, the ceramic body of the petrol particulate filter is fragile.

CAUTION: Wear safety goggles and protective gloves.
Conduct all work in appropriate personal protective equipment only.
Swarf resulting from sawing or grinding components could get into your eyes.

Necessary preliminary work:

Remove the TENSION STRUT.
Remove the REAR RIGHT TENSION STRUT .
Use a suitable jack to support and secure the exhaust system against falling.

Removal:

Equipment specification 1 (ribbon clamp):

Slacken nut (1).

Slacken ribbon clamp (2).

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Equipment specification 2 (V-clip):

Release clamp (1).

Replace clamp (1).

Parts: Clamp.

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Unlock and disconnect plugs (1).

Unscrew nuts (2).

Remove exhaust system (3).

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Installation:

Feed in exhaust system (3) and install.

Tighten down nuts (2).

Tightening torque, refer to: 18 20 3AZ .

Attach and lock connector (1).

Connector (1) must engage audibly.

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Equipment specification 1 (ribbon clamp):

Cut weld seam (1) using commercially-available tool.

Remove ribbon clamp (2).

Replace the ribbon clamp (2).

Parts: Ribbon cable clamp

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Installation note:

Screw the exhaust system without tension.

Tighten the new ribbon clamp (2).

Tightening torque, refer to: 18 20 1AZ .

Tighten nut (1).

Tightening torque, refer to: 18 20 2AZ .

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Equipment specification 2 (V-clip):

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

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Mount sealing ring (1) on the exhaust system.

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

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Bend all sheet metal tabs over with a suitable tool, except those in the marked areas.

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Mount V-clip (1) on the sealing ring (2).

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

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Make sure that the V-clip rests against the sheet metal tabs after mounting (marks).

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

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Make sure that V-clip (1) is fitted correctly.

Tighten clamp (1).

Tightening torque, refer to: 18 20 1 AZ .

Tighten nut (2).

Tightening torque, refer to: 18 20 2AZ .

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Required follow-up work:

Install the REAR RIGHT TENSION STRUT.
Install the TENSION STRUT.
Check exhaust system for leak tightness.