Removal and installation of the exhaust system - ra49006027000x(7000)
A. Model 201 with engine 602.96, B. Model 124 with engines 602.96, 603.96, C. 126 with engines 603.96/97, D. 140 with engine 603.971
- Model 201 with Engine 602.96
- Without Oxidation Catalytic Converter
- With Oxidation Catalytic Converter Fig 2: Identifying Exhaust System Remove/Install Components - With Oxidation Catalytic Converter (Model 201 With Engine 602.96)
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Rear muffler (9) remove, install, check for damage, renew if necessary.
Tightening torque of nut (27) 20 Nm.Rubber buffer (13) check for wear, renew if necessary. Pipe clamp (21) renew. Centre muffler (7) remove, install, examine for signs of damage, renew if necessary. Hexagon bolts (8) and self-locking nuts (4) renew. Tightening torque 20 Nm. Centered seal (5) examine for signs of damage, pay attention to correct seating. Retaining bar (6) with Belleville spring washers remove, re-fit. Tightening torque 7 Nm. (17) and self-locking nuts (16) Installation note
Check parts and renew if necessary.
Belleville spring washers.Front exhaust pipe with flexible hose (2) remove, install, check flange for damage, tighten evenly and assemble flexible hose free of tension. Renew self-locking nuts (16), tightening torque 20 Nm.
- Model 124 with Engines 602.96, 603.96
- Without Oxidation Catalytic Converter
- With Oxidation Catalytic Converter Fig 4: Identifying Exhaust System Remove/Install Components - With Oxidation Catalytic Converter (Model 124 With Engines 602.96, 603.96)
Rear muffler (9) remove, install, check for damage, renew if necessary.
Tightening torque of nut (27) 20 Nm.Rubber buffer (13) check for wear, renew if necessary. Pipe clamp (21) renew. Centre muffler (7) remove, install, check for signs of damage, renew if necessary. Bolts (8) and self-locking nuts (4) renew. Tightening torque 20 Nm. Centered seal (5) check for damage, ensure correct position. Retaining bar (6) with Belleville spring washers (17) and self-locking nuts (16) detach, mount, tightening torque 7 Nm.
Installation note
Test parts and renew if necessary.
Belleville spring washers.Front exhaust pipe with flexible hose (2) remove, install, check flanges for signs of damage, tighten evenly and install flexible hose free of tension. Renew self-locking nuts (16). Tightening torque 20 Nm.
- Model 126 with Engines 603.96/97
Rear muffler (9) remove, install, check for damage, renew if necessary.
Tightening torque of nut (27) 20 Nm.Rubber buffer (13) check for wear, renew if necessary. Pipe clamp (21) renew. Centre muffler (7) remove, install, check for signs of damage, renew if necessary. Bolts (8) and self-locking nuts (4) renew. Tightening torque 20 Nm. Centered seal (5) check for damage, ensure correct position. Retaining bar (6) with Belleville spring washers detach, mount, tightening torque 7 Nm. (17) and self-locking nuts (16) Installation note
Test parts and renew if necessary.Front exhaust pipe with flexible hose (2) remove, install, check flanges for signs of damage, tighten evenly and install flexible hose free of tension. Renew self-locking nuts (16). Tightening torque 20 Nm. - Model 140 with Engine 603.971
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Rear muffler (9) remove, install, check for damage, replace if necessary.
Tightening torque of nut (27) 20 Nm.Rubber buffer (18) check for wear, replace if necessary. Pipe clamp (21) replace. Center muffler (7) remove, install, check for signs of damage, replace if necessary. Bolts (8) and self-locking nuts (4) replace. Tightening torque 20 Nm. Centered seal (5) check for damage, ensure correctly located. Bolts (11) at transmission flange unscrew, screw on. Pay attention to washers (12). Tightening torque 20 Nm as reference value. Nuts (6a) at intermediate piece of front exhaust pipe, unscrew, screw on.
Tightening torque 20 Nm as reference value.Supporting bracket (10) take off, install. Nuts (23) and rubber damper (14) remove, install.
Check parts, replace if necessary.Threaded plate (6) take out, insert. Replace if necessary. Front exhaust pipe with flexible hose (2) remove, install, check flanges for signs of damage, tighten evenly and install flexible hose free of tension.
Replace self-locking nuts (3), tightening torque 20 Nm. - Notes Regarding Removal and Installation Work
The removal and installation of the exhaust system is not explained in full, but reference is made only to particularly important points which require to be observed when removing or installing or when renewing a part, e.g. of the rear muffler with push-fit joint.
Removal
- Detach rear section of the noise encapsulation when working on the front exhaust system (except Model 126.1).
- Check hangers for re-use, renew if necessary.
- Before installing the exhaust system, ensure that the flange to the exhaust manifold is not twisted; align flange if necessary. Clean combustion residues off tapered connection fittings of the pipes and centered seals (2, 5 and 22) with emery cloth, if necessary.
Installation
Renewing rear muffler.
- Position new rear muffler with push-fit joint precisely over removed system and mark length of pipe of new rear muffler on the removed system.
Models 124, 126, 201: Size "A"=80 mm (tolerance minus 10 mm)
Model 140: Size "A"=100 mm
Cut through the pipe "A" mm from the mark in the direction of the rear muffler to ensure a push-fit depth of 70-80 mm.
- Always renew self-locking hexagon nuts.
- Do not tighten the flange joint to the exhaust gas turbocharger (arrows) until the complete system has been suspended in the rubber rings. Tightening torque of the hexagon nuts 20 Nm.
Arrangement on Models 124, 201
When assembling the front exhaust system to the exhaust gas turbocharger, do not allow the weight of the system to apply tensile stresses to the flexible hose. Use the side support on the transmission as a base.
- Install rear exhaust system with center and rear mufflers, attaching the exhaust system to the rubber hanger on the rear axle mount at the same time.NOTE: Use a suitable hook to attach the rubber rings on the rear muffler.
Arrangement on Model 124.133
- Install centered seal at the flange joint and ensure it is correctly located. Tightening torque of self-locking hexagon nuts 20 Nm (arrows).
Models 124 without catalytic converter, 126, 201
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Models 124 with catalytic converter, 140
- Models 124, 126, 201
Install rear mufflers so that the retaining bars of the rear mufflers are positioned 10 mm ahead of the brackets on the frame floor to ensure the correct installed position when the exhaust system expands (arrows).
Arrangement on Model 124.133
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Model 140
When inserting the exhaust system, ensure that the projection "a" of the bracket at the tail silencer beyond the rubber bush is not more than 3-5 mm when cold.
Arrangement on Model 140
NOTE: This relates only to repair versions of mufflers with push-fit joint between center and rear mufflers. - Install pipe clamp at the push-fit joint between center and rear mufflers so that the clamp is facing outwards toward the handbrake cable (arrow).
If car is fitted with automatic locking differential (ASD), ensure sufficient clearance between hydraulic line and pipe clamp. Turn hydraulic line away slightly, if necessary.
Arrangement on Models 124, 201
- Models 124, 126, 201: Install exhaust side support free of tension. Tightening torque of self-locking hexagon nuts on clamping bar 7 Nm, hexagon bolts of side support on transmission 20 Nm.
Arrangement on Model 124.133
Model 140: Tightening torque of selflocking nuts at bracket 20 Nm, hexagon bolts of side support on transmission flange 20 Nm.
Arrangement on Model 140
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Note Models 124, 126, 201
Install 4 Belleville spring washers on each side of the retaining bar so that the curved faces are facing away from each other (as shown in figure).
- Run engine and examine exhaust system for signs of leaks.
Models 124, 126, 201
- Install noise encapsulation.