Contents: Installation ⬇ Replacing the middle and rear…⬇ Alignment of the exhaust system…⬇ Checking the exhaust system for leaks ⬇
Lift the engine cover at the sides "arrow A" and remove it forward "arrow B".
Remove the charge air pipe to the right. Remove the intake manifold flap motor "V157". Unscrew the bracket with the exhaust gas pressure sensor 1 "G450". Remove the cylinder head cover. Remove the intake manifold with the EGR valve "B", the EGR potentiometer "G212" and the EGR regulator OG/338-. Remove the temperature sensor in front of the particulate filter.
Unscrew the pressure line in the particulate filter. Unscrew the heat shield. Unscrew the temperature sensor behind the particulate filter. "G527" "pos. 1" from the outlet pipe behind the particulate filter. Unscrew the support pipe "2" for the pressure sensor 1 for the outlet pipe "G450".
Disconnect the plug-in electrical connector for the lambda probe "G39", the temperature sensor in front of the particulate filter and behind it. Unscrew the lambda probe "G39".
Remove the pressure pipe with the G450 sensor and the heat-protective casing. Remove the particulate filter mounting bracket. Remove the screw between the top support and the particulate filter. Unscrew the "arrow" screws on the particulate filter holder. Remove the lower engine cover. Having released the axle suspension mounting beam, center it in the service position. Loosen the double clamp nuts.
Unscrew the spring suspension clamp of the "arrow" exhaust system.
Important: The connection element at the front of the exhaust pipe must not be positioned at an angle greater than 10° - risk of damage.
Remove the front section of the exhaust pipe with the particulate filter.
Installation
Installation is carried out in the reverse order of actions. In this case, the following instructions must be observed.
Important: Replace seals and self-locking nuts. All hose connections must be secured with appropriate hose clamps. Any cable clamps that were loosened during removal must be reattached in the same position during reinstallation. When installing the connecting hose with a push-in connection, ensure that the locking clamp "arrow" engages behind the retaining tabs "A." Align the exhaust system so that it is free of internal stress. After replacing the particulate filter, it is necessary to carry out the adjustment in the "Controlled functions" function - VAS 5051.
Unscrew the exhaust gas pressure sensor 1 "G450". Remove the propeller shaft housing from the engine.
Replacing the middle and rear sections of the exhaust manifold
For separate replacement of the middle and rear parts of the exhaust pipe, respectively, a cutting point is designated on the connecting pipe, indicated on the surface of the pipe by a stamped recess. Cut the exhaust pipe at a right angle at the cut point "arrow 1" with a body saw. When installing, position the double clamp "4" on the side marks "arrow 2" and "arrow 3".
Install the double clamp so that the ends of the screws do not protrude through the bottom edge. Align the exhaust system so that it is free of internal stress. Tighten the double clamp screws evenly to a torque of 23 Nm. The screw connection faces right.
Alignment of the exhaust system without internal stress
The exhaust system is aligned in a cold state. Loosen the double clamp screws between the front and middle sections of the exhaust pipe. Move the rear section of the exhaust system so far forward that the pre-tension on the front spring suspension of the rear section of the exhaust pipe "a" = 2...5 mm.
Reinstall the double clamp so that the ends of the screws do not protrude through the bottom edge. The screw connection is directed to the right.
After moving the double clamp to a distance of "a" = 5 mm in front of the mark on the exhaust catalytic converter pipe, tighten the screw connections evenly with a torque of 23 Nm.
Checking the exhaust system for leaks
Start the engine and let it run at idle speed. Block the rear muffler exhaust pipes while checking for leaks. Check the cylinder head/exhaust manifold, turbocharger/front exhaust manifold, etc. connections by listening for leaks. Eliminate any identified leaks.
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