Exhaust System Removal and Installation

Tools

• Metric wrench set
• Metric socket set
• Pry bar
• Penetrating lubricant
• Jack stands

Other Procedures Referenced

• FUEL-09 — Intake Manifold Removal (required for one-piece crossover pipe removal only)

Exhaust System Removal — Normally Aspirated Cars

1. Disconnect the O₂ sensor near the back of the firewall and drop the sensor connector down to the exhaust pipe.
2. Remove the CO sample tube from the exhaust pipe. This tube has been removed and capped on many cars — it is prone to rusting out and causing exhaust leaks. If still present, the top end of the tube is located at the back of the camshaft housing near the engine lifting ring.
3. Remove the six nuts and bolts attaching the exhaust pipe to the exhaust manifolds.
4. Support the exhaust with blocks or jack stands.
5. Remove the nuts and bolts on the hanger in front of the catalytic converter, at the rear of the catalytic converter, and at the rear of the muffler.
6. Lower the exhaust system from the car.

Crossover Pipe Back Removal — Turbo (Leaving Crossover Pipe In)

1. Disconnect the O₂ sensor near the back of the firewall and drop the sensor connector down to the exhaust pipe.
2. Remove the CO sample tube from the exhaust pipe (see note in step 2 above).
3. Remove the nuts on the turbocharger discharge pipe flange (near the O₂ sensor).
4. Remove the nuts and bolts on the triangle-shaped flange at the wastegate discharge.
5. Support the exhaust with blocks or jack stands.
6. Remove the nuts and bolts on the hanger in front of the catalytic converter, at the rear of the catalytic converter, and at the rear of the muffler.
7. Lower the exhaust system from the car.

Crossover Pipe Removal — Turbo

Note: This procedure requires intake manifold removal using FUEL-09.

a. Remove the intake manifold. b. Unplug the turbocharger cooling pump and remove the cooling pump mounting bracket. c. Place rags under the hose on the discharge of the cooling pump going to the turbocharger. d. Loosen the hose clamp on the 90° bend cooling water supply pipe to the turbocharger. e. Slide the hose (still attached to the cooling pump) off the pipe and move it toward the front of the car. Some coolant will come out of the turbocharger cooling jacket — keeping the cooling pump and supply hose above the level of the coolant expansion tank minimizes coolant loss. f. Using a 22 mm wrench and a 27 mm wrench, remove the 90° bend cooling water supply pipe and the threaded nipple on the jacket water supply to the turbocharger. g. From above, remove the two turbocharger inlet flange nuts and bolts at the top of the flange and the nut and bolt on the bottom nearest the front of the car. These require two 15 mm wrenches, or a wrench and 15 mm socket. h. From above, disconnect the O₂ sensor electrical connector (round connector on the mounting bracket at the back of the intake manifold). i. From under the car, remove the O₂ sensor. j. Remove the turbocharger inlet flange bolt at the bottom of the flange nearest the back of the car. A 15 mm wrench or socket is needed for the bolt — the nut is tack-welded to the flange.

1. Remove the six nuts and bolts attaching the crossover pipe to the exhaust headers.
2. For models with a two-piece crossover pipe, remove the nuts and bolts on the triangle-shaped flange between the crossover pipe and the wastegate.
3. For cars with a one-piece crossover pipe, the wastegate must be removed to extract the crossover pipe.
4. Using a pry bar, separate the crossover pipe from the exhaust headers and lower it from the car.

Exhaust Manifold Removal

1. Remove the six nuts and bolts on the flanges between the exhaust manifolds and the exhaust/crossover pipe.
2. Remove the two Allen head bolts attaching the coolant return pipe to the cam housing.

Note: It may be necessary to remove the coolant return pipe completely to clear the exhaust manifolds. This requires partially draining the cooling system.

3. To remove the exhaust manifold studs, loosen the exhaust nut several turns, then thread a second nut onto the stud. Tighten the outer nut against the inner nut while holding the inner nut with a second wrench. Then turn the inner nut counter-clockwise to back the stud out of the head. If both nuts turn together, tighten the outer nut further before retrying.
4. Remove the exhaust manifolds from the car.

Installation

Installation is essentially the reverse of removal. Use new hardware when reinstalling the exhaust system. On turbocharged cars with one-piece crossover pipes, fill and vent the cooling system after installation (see cooling system procedures).

Torque specification:

• Header-to-exhaust flange nuts: 20 Nm (15 ft-lb)