Remove & install complete exhaust system (Cooper S)

WARNING: Danger of combustion 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 technician.

Preliminary work needed:

Use a suitable jack to support and secure the exhaust system against falling.

Removal:

If fitted:

Loosen the screws along the arrows.

Remove cover (1).

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Version 1 (ribbon clamp):

Release clamp (1).

Replace clamp (1).

Parts: Clamp.

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Version 2 (V-ribbon clamp):

Release clamp (1).

Replace clamp (1).

Parts: Clamp.

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Loosen the screws along the arrows.

Feed out connecting supports (1) and remove.

Feed out connecting supports (2) and remove.

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Loosen screws (1).

Feed out connecting supports (2) and remove.

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Spray rubber mount (1) with lubricant and detach from exhaust system.

Replaced damaged rubber mounts.

Parts: rubber mount

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Slacken right nut (1).

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Slacken left nut (1).

Lower and remove exhaust system with assistance of a second technician,

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Preparation for installation:

Check rubber mount for damage, replace if necessary.

Installation:

Version 1 (ribbon clamp):

Install new snap ring (1).

Install exhaust system and connect to the catalytic converter with the assistance of a second technician.

Tighten clamp (1).

Tightening torque 18 20 1AZ .

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Version 2 (V-ribbon clamp):

Release nut (1) and remove sealing ring (2),

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Mount sealing ring (1) on exhaust system.

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

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Bend all metal sheets round, apart from those in the marked areas, with a suitable tool.

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

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

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Make sure that, after mounting, the V-ribbon clamp is on the metal sheets (markings).

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

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Ensure correct fit of the V-ribbon clamp (1).

Tighten screw (2).

Tightening torque 18 20 1AZ .

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Tighten left nut (1).

Tightening torque 18 20 2AZ .

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Tighten right nut (1).

Tightening torque 18 20 2AZ .

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Connect rubber mount (1) to rear silencer.

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Install the connecting support (1).

Tighten screws along arrows.

Tightening torque 18 30 4AZ .

Install the connecting support (2).

Tighten screws along arrows.

Tightening torque 18 30 5AZ .

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Install front connection carrier (2).

Tighten down screws (1).

Tightening torque 18 30 6AZ .

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If fitted:

Position cover (1).

Tighten screws along arrows.

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Required follow-up work

Check exhaust system for leak tightness.