Exhaust system - inspection, removal and refitting

Inspection
1 The exhaust system should be examined for leaks, damage, and security at regular intervals. To do this, apply the handbrake, then start the engine and allow it to idle. Lie down on each side of the vehicle in turn and check the full length of the exhaust system for leaks, while an assistant temporarily places a wad of cloth over the tailpipe. If a leak is evident, stop the engine and use a proprietary repair kit to seal it. If an excessive leak or damage is evident, renew the relevant section of the exhaust system. Check the rubber mountings for deterioration and renew if necessary.

Removal
2 To remove the exhaust system, jack up the front and rear of the vehicle and support on axle stands (see “Jacking and Vehicle Support”).

3 If desired, the exhaust downpipe can be removed independently of the remainder of the system, and similarly the main part of the system can be removed, leaving the downpipe in place.

4 To remove the downpipe, unscrew the securing nuts and disconnect the downpipe from the manifold. Recover the gasket.

Unscrew the two nuts and bolts, and separate the downpipe flanged joint from the remainder of the system. Withdraw the downpipe (see illustrations).

27.4a Exhaust downpipe-to-manifold  flanged joint
27.4a Exhaust downpipe-to-manifold flanged joint viewed from underneath vehicle

27.4b Exhaust downpipe-to-main system  flanged joint
27.4b Exhaust downpipe-to-main system flanged joint

5 To remove the main section of the exhaust system leaving the downpipe in place, unscrew the two securing nuts and bolts and separate the flanged joint from the downpipe.

Unhook the rubber mountings and withdraw the system from underneath the vehicle. The number and type of rubber mountings varies according to model (see illustrations).

27.5a Rear exhaust section mounting -  Hatchback model
27.5a Rear exhaust section mounting - Hatchback model

27.5b Rear exhaust mounting - P100 model
27.5b Rear exhaust mounting - P100 model

If necessary to avoid confusion, note how the mountings are fitted to enable correct refitting. Note that on P100 models the system must be manipulated to pass over the rear axle.

Refitting
6 Refitting is a reversal of removal, but ensure that all mating faces are clean, and fit a new gasket between the downpipe and manifold (see illustration).

27.6 Fit a new downpipe-to-manifold  gasket
27.6 Fit a new downpipe-to-manifold gasket

Do not fully tighten the joint fittings until the system is in position and correctly aligned in its mountings under the vehicle. Ensure that no part of the exhaust system is closer than 25.0 mm (1.0 in) to the underbody.

7 Service replacement exhaust systems are available in three sections; downpipe, centre section and rear section. The service replacement sections fit together using socket joints, therefore the centre section of a production exhaust system cannot be renewed without also renewing the rear section.

8 To renew the centre and/or rear section(s) of the exhaust system, first remove the main system as described in paragraph 5.

9 To fit a service replacement rear section to a production system, use a hacksaw to cut through the pipe at the applicable point shown (see illustrations).

27.9a Cutting point when fitting a service replacement exhaust system section
27.9a Cutting point when fitting a service replacement exhaust system section - Saloon, Hatchback and Estate models

X = 1639 mm for all models up to 1987 except 1.3 and 1.6 litre Hatchback X = 1681 mm for 1.3 and 1.6 litre Hatchback models up to 1987 X = 2063 mm for all models from 1987

27.9b Cutting point when fitting a service replacement exhaust system section
27.9b Cutting point when fitting a service replacement exhaust system section - P100 models

X = 226 mm

Apply exhaust
sealant to the mating surfaces of the two sections, then push the two sections together and fit a U-bolt clamp to the centre of the joint. Do not fully tighten the U-bolt clamp nuts until the system is in position and correctly aligned in its mountings under the vehicle.

10 To renew a service replacement section, unscrew the nuts and remove the U-bolt clamp from the joint. Tap around the joint to break the seal, and separate the centre and rear sections. Ensure that the joint mating surfaces are clean, then apply exhaust sealant, push the new section onto the remaining section, and fit the U-bolt clamp to the centre of the joint. Do not fully tighten the U-bolt clamp nuts until the system is in position and correctly aligned in its mountings under the vehicle.

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