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Exhaust system 49

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49 Exhaust system

Job No. Removal and installation of exhaust system

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49-l 00

Removal and installation of exhaust system

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Hex screw .................... Front exhaust pi e. ................... Self-ocking hex, nut. ................... Self-ocking hex. nut. ..................... Sinter-sealing ring. ....................... Holding clamp. . . . . . . . . . . . . . . . . . . . . . . . Center muffler. Hex. screw ......................... Rear mufler Lateral sup ort 10 .......................... Hex. screw 1 Washer 12 ....................... Rubber buffer. 13 ......................... Rub er disk 14 Spacing sle ve 15 ................... Self-ocking hex. nut. 16 .......................... Cup spring 17 ......................... Rub er ring 18 Hex. screw 19 Washer 20 Pipe clamp 21 ........................... Snap ring 2 Hex. nut 23 .......................... Hex. screw 24 ...................... Suspension plate 25 26 Clamping plate 1 2 3 4 5 6 7 8 9

Check flanges for damage Renew, 20 Nm Renew, 20 Nm Check for damage, check for corect seat Check for re-use Check for damage Check for damage 20 Nm Check for wear Check for damage Renew, 7 Nm Renew Check for damage and wear

Renew 20 Nm Check for damage and wear

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Removal and instalation of exhaust sytem is not explained fuly, but atention is caled to particularly important items only, which must be observed during removal and instalation or when renewing parts, e.g. the rear mufler with plug con ection.

Remova I

1 Check suspension parts for re-use and renew, if required. 2 Prior to asembly of exhaust sytem, make sure that the flange for exhaust manifold is not distorted and align flange, if required. Clean cone connections of pipes (2 and 22), if required, with emery glos from combustion residue.

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Installation

Renewing rear mufler. 3 Place new rear muffler with plug connection accurately above removed system and mark pipe length of new rear muffler on removed installation. Cut pipe 80 mm from mark (tolerance minus 10 mm) in direction of rear muffler to obtain a plug-in depth of 70-80 mm.
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4 Always renew self-locking hex. nuts on principle. 5 Uniformly tighten flange connection to manifold. Tightening torque of self-locking nuts 20 Nm.

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6 Mount rear exhaust system with center and rear muffler, while simultaneously engaging exhaust system in mounting rubber on rear axle carrier.

7 Mount sinter-sealing ring (5) on flange connection and pay attention to correct seat. Tightening torque of self-locking hex. nuts 20 Nm.

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22

2 5 6 7 18 22

Front exhaust pipe Sinter-sealing ring Self-locking hex. nut Hex. screw Flange Rear exhaust pipe

8 Engage rubber rings with suitable hooks to rear damper.

9 Mount rear damper in such a manner that the holding clamp of the rear damper is approx. 10 mm in front of holders on frame floor, so that the correct installation position is assured (arrows) in the event of an elongation of exhaust system. Note: The above refers to mufflers in repair version with plug connection between center and rear muffler only.

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10 Mount exhaust lateral sup ort
fre of tension.

Tighteni g torque of self-ocking hex. nuts on clamp 7 Nm, hex. screws of lateral sup ort on transmision 20 Nm.

Note: Mount 4 cup springs each per side to clamp in such a man er that the respective crowns are located op osite each other (as shown in Fig.) 11 Run engine and check exhaust sytem for leaks.

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