Replacing Front Silencer

Information 

The procedure is described for a vehicle with a twin-branch exhaust system. These steps are not necessary on vehicles with a single-branch exhaust systems.

Information 

Fit new exhaust clamp (clamping sleeve), seal and screw. Apply a light coating of high-temperature grease on the sleeve before installation to facilitate fitting.

Fit new suspension rubbers or holders if necessary.

1. Unscrew screws -4-  on transmission bridge holders -3-  . Loosen ball clamps -2-  between the catalytic converters and front silencer -1-  .

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   Exhaust system to transmission bridge (illustration shows a twin-branch exhaust system)

2. For vehicles with sports exhaust system:  Pull off vacuum hose -1-  on vacuum unit for exhaust flap -2-  .

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   Vacuum hose for exhaust system

3. Secure decoupling elements -1-  to prevent them from moving.
   1. 3.1 Secure decoupling elements -1-  with wire -2-  on transmission support -3-  .

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   Securing decoupling elements (illustration shows a twin-branch exhaust system)

4. Loosen centre exhaust system mount -2-  . Unscrew screws -1-  .

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   Centre exhaust system mount

   Information 

   • Before loosening the front silencer, the rear silencers must be supported with a transmission jack or held by another person. 
5. There is a small notch on the underside of the exhaust pipes. The notch marks the connection point -Arrows-  .

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   Rear silencer connection point

6. Place the pipe cutter chain > Nr.166 - chain pipe cutter  or > Nr.166-1 - ratchet pipe cutter  (or similar tool) around the exhaust pipe near the notch and engage at the other end of the pipe cutter. Then clamp the chain firmly by turning the handle -Arrow-  .

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   Placing pipe cutter chain around exhaust pipe (similar to illustration)

7. Swivel the pipe cutter to and fro in wide movements -Arrows-  until the pipe is cut through. While doing this, keep re-tensioning the chain by turning the handle.

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   Cutting through pipe using pipe cutter (similar to illustration)

8. Fit new suspension/hang-on pads and holders or convert them from the old part if necessary.
9. Push new exhaust clamp onto the exhaust pipe.
10. Lift the rear silencer into installation position with the help of a second mechanic or using a transmission jack.
11. Fit exhaust system on transmission support.
    1. 11.1 Fit and tighten screws -4-  on transmission support holders -3-  .

       > Tightening torque 23 Nm (17 ftlb.) 

    2. 11.2 Removing wire for securing decoupling elements
    3. 11.3 Attach new ball clamps -2-  to the connection between the catalytic converters and front silencer.
       1. 11.3.1 Tighten ball clamps -2-  .

          > Tightening torque 35 Nm (26 ftlb.) 

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          Exhaust system on transmission support

12. Fit holder for centre exhaust system mount -2-  .
    1. 12.1 Fit and tighten screws -1-  .

       > Tightening torque 23 Nm (17 ftlb.) 

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       Centre exhaust system mount

13. For vehicles with sports exhaust system:  Connect vacuum hose -1-  to vacuum unit for exhaust flap -2-  .

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    Vacuum hose for exhaust system

14. Align exhaust clamp -Arrows-  and tighten screws.

    > Tightening torque 33 Nm (24 ftlb.) 

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    Positioning clamping sleeves

15. Install tunnel strut -3-  .
    1. 15.1 Fit and tighten screws -1 and 2-  .

       > Tightening torque 50 Nm (37 ftlb.) 

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    Tunnel strut