Exhaust Pipe: Service and Repair
WM 263419 Removing and installing tailpipe
Tools
Technical values
Preliminary work
Information
This description also applies for all other tailpipe variants (single or dual pipe)
1. In the case of welded tailpipes, remove exhaust system. -> 260119 Removing and installing exhaust system Service and Repair. Under certain conditions (e.g. rear damage), the tailpipe can be replaced in installed condition after removing the rear apron.
1.1. Set down exhaust system, preventing it from slipping and falling.
2. In the case of screwed tailpipes, convert tailpipes. => Tightening torque: 30 Nm
Sport tailpipe cover
Information
Information on assembling tailpipe covers
Information
- On vehicles from model year A, there may not be enough exhaust pipe protruding from the rear silencer after the tailpipes are cut.
- If insufficient exhaust pipe length to reliably secure a tailpipe using a screw-type clamp is left protruding from the rear silencer after the tailpipes are cut, the rear silencer must be replaced as preliminary work (the rear silencer has a longer exhaust pipe).
- On vehicles from model year B, there is sufficient exhaust pipe length protruding from the rear silencer after the tailpipes are cut.
Overview of exhaust system cuts
Standard cutting guide
Turbo cutting guide
V6 cutting guide
Removing tailpipe
Information
- The tailpipe must be cut all around along the weld seam.
- At least 26 mm of straight exhaust pipe length must be left all around after the cut is made. If insufficient exhaust pipe length to reliably secure a tailpipe using a screw-type clamp is left protruding from the rear silencer after the tailpipes are cut, the rear silencer must be replaced as preliminary work (the rear silencer has a longer exhaust pipe).
- The cut must be made at the border of the weld seam at the exhaust pipe so that there are no weld seam residues to roughen and mill.
- The surface of the exhaust pipe must not be roughened, ground or milled. These processes produce a rough and uneven component surface on the exhaust pipe, which prevents reliable fixing of the new screw-type clamp.
1. If control boxes for exhaust valves are fitted, remove them to allow better access.
2. Cut off welded tailpipe with an extra-thin, suitable cutting disc (e.g. high-performance cutting disc Nr.129-1 ) at the second weld seam downstream from the rear silencer (illustrated position) => Cut on welded standard tailpipe. Remove the tailpipe. The straight exhaust pipe must remain.
Cut on welded standard tailpipe
3. Rework exhaust pipe and prepare for assembly of screwed tailpipe.
- Deburr saw cut on inside and outside of exhaust pipe.
- Using a sharp hand chisel, carefully chip off remaining weld spatter on exhaust pipe by hand.
- If necessary, manually restore exhaust pipe to roundness.
- Manually remove rust from surface using suitable polishing agents (abrasive cloth).
- The exhaust pipe must not be roughened, ground or milled. These processes produce a rough and uneven component surface on the exhaust pipe, which prevents reliable fixing of the new screw-type clamp. => Prohibited roughening process on the surface of the exhaust pipe => Calibration of exhaust pipe
Prohibited roughening process on the surface of the exhaust pipe
Calibration of exhaust pipe
Installing tailpipe
1. Push replacement tailpipe onto exhaust pipe and tighten the clamp slightly. => Installing replacement tailpipe
Installing replacement tailpipe
Installation position of standard tailpipe covers
Installation position of Turbo individual covers
Installation position of V6 tailpipe covers
2. Bring exhaust system into installation position. For details, see -> 260119 Removing and installing exhaust system Service and Repair
3. Align tailpipes with respect to the rear apron. Ensure even distance and gap dimensions (visual inspection!).
Alignment => The tailpipe covers should have the same exhaust spacing on the left and right. If there are differences in the exhaust length relative to the rear apron, the other tailpipe cover must also be replaced. For example -2 and 3- and -2 and 3-. The "Standard" illustration -2 and 3- shows all the ideal spacings.
Standard adjustment dimensions
Turbo adjustment dimensions
V6 adjustment dimensions
Sport adjustment dimensions
4. Tighten the tailpipes. => Tightening torque: 40 Nm (30 ftlb.)
5. Fit control boxes for exhaust valves if necessary.
Subsequent work
1. Install rear underbody panel, -> 519419 Removing and installing rear underbody panel 519419 Removing and Installing Cover for Rear Underbody