Centre Muffler and Front Exhaust Pipe, Remove and Install

Note: This procedure is described on a Z 18 XE engine. Proceed analogously for other engine versions.

Front exhaust pipe must be prevented from swinging uncontrollably a bend in the flex pipe as small as 10 15 degrees may result in damage with subsequent total failure of the flex pipe!

When removing centre muffler, main catalytic converter or exhaust manifold with pre-catalytic converter, the exhaust system must be prevented from swinging uncontrollably. For this purpose, use suitable means (e.g. wire) to secure the exhaust system to the vehicle underbody.

Remove If present: Remove lower engine compartment cover see operation "Lower Engine Compartment Cover, Remove and Install" in group "A". Detach fastening bolts (2) of front exhaust pipe (1). Disconnect wiring harness plug (3) for catalytic converter check oxygen sensor. For Z 20 LET engine: Expose wiring harness for catalytic converter check oxygen sensor see operation "Oxygen Sensor Catalytic Converter Check, Remove and Install" in group "J".

Detach fastening bolts (1) from rear muffler flange connection. Take centre muffler out of shock absorber ring - remove centre muffler with front section of exhaust pipe

Install Replace gasket of front exhaust pipe.

Note: Front exhaust pipe must be prevented from swinging uncontrollably a bend in the flex pipe as small as 10 15 degrees may result in damage with subsequent total failure of the flex pipe! Insert centre muffler into damping rings. Attach rear muffler flange connection with new seal ring and new fastening bolts do not tighten yet.

Attach front exhaust pipe with new fastening nuts tightening torque 20 Nm / 15 lbf. ft. For X 16 SZR engine and hex-head bolt version: attach front exhaust pipe section with new gasket and bolts lubricated with mounting paste (white) to exhaust manifold - tightening torque 35 Nm / 26 lbf. ft. For X 16 SZR engine and hexagonal nut version: attach front exhaust pipe section with new gasket and new nuts and bolts exhaust manifold - tightening torque 45 Nm / 33 lbf. ft. For Z 16 SE engine: front exhaust pipe section with new gasket and new nuts to catalytic converter - tightening torque 45 Nm / 33 lbf. ft. Align rear muffler. Tighten rear muffler flange connection - tightening torque 8 Nm / 6 lbf. ft. For Z 20 LET engine: Connect wiring harness for catalytic converter check oxygen sensor see operation "Oxygen Sensor Catalytic Converter Check, Remove and Install" in group "J". Connect wiring harness plug for catalytic converter check oxygen sensor. If present: Install lower engine compartment cover see operation "Lower Engine Compartment Cover, Remove and Install" in group "A".