AR49.10-P-7000TB Remove/Install Complete Exhaust System

Remove/install complete exhaust system

Part 1:

Part 2:

DANGER:
- Risk of death. Death may result if vehicle slips or topples from the lifting platform.
- Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer.
- Risk of injury to skin and eyes from handling hot or glowing objects.
- Wear safety gloves, protective clothing and safety glasses, if necessary.

CAUTION: Read notes on self-locking nuts and bolts.

1 Remove rear part of engine compartment paneling
2 Remove crossmember (35).
3 Unclip electrical connectors (G3/3x1 up to G3/6x1) of OO22 sensors and feed lines of OO22 sensors from retaining clamps
4 Disconnect electrical connectors (G3/3x1 up to G3/6x1) of OO22 sensors.
5 Slacken bolts (1a)
6 Dismount left and right catalytic converter bracket (1) from firewall three way catalytic converters (157/1, 157/2)
7 Support exhaust system with transmission lifter and transmission platform.
8 Dismount left and right firewall three way catalytic converter (157/1,157/2) from exhaust manifolds.

NOTE: Installation: Check rivet nuts in exhaust manifold, replace if required, Replace rivet nuts in exhaust manifold.

9 Unhinge left and right rear muffler (9a) from exhaust rubber mounts (9/1, 9/2).

NOTE:
- Use lubricant.
- Installation: Check exhaust rubber mounts (9/1, 9/2), replace if worn.

10 Lift out exhaust system

NOTE: Lower transmission jack and tilt exhaust system approximately 45 degrees about longitudinal axis.

- Read notes on disposing of catalytic converters.

11 Install in the reverse order

Inspect
12 Inspect installation position and clearance of exhaust system

NOTE: The exhaust system must be installed free of stress, if necessary, Align exhaust system.

DANGER:
- Risk of accident. Accidents may result if the vehicle starts off unintentionally with the engine running. Risk of injury as working around the engine during start-up or while running may result in contusions and burns.
- Secure vehicle to prevent it from moving.
- Wear closed and snug-fitting work clothes.
- Do not grasp hot or rotating parts.

13 Conduct engine test run and inspect exhaust system for leaks.