Diesel Exhaust System

Layout

Work only on a cold system. The catalytic converter sits at an angle straight under the exhaust manifold. A short flexible pipe follows, then the factory rear section with centre and rear silencers in one piece. Later cars may carry a diesel particulate filter after the flex, flanged at both ends.

Rubber hangers carry the run. A rigid bracket supports the converter from below. Heat shields bolt or clip to the floor above the pipe so the cabin and tank stay cooler.

Inspection

Raise the car safely or use a pit. Look for open seams, holes, crushed pipes, loose clamps, and black sooty stains at joints. Move the silencers by hand: if they can kiss the floorpan or a suspension arm, renew the rubbers or twist the joints for clearance. Rattles are often a loose shield or a collapsed baffle inside a box.

Renewal Notes

To replace either silencer on the original one-piece rear, cut between the centre and rear boxes. Offer the new section first and mark the cut so the sleeves still overlap. Work from the back forward. Soak flange nuts in penetrant. Renew flange, clamp, and converter-to-manifold nuts; rusted ones round off next time. Clean mating faces hard. Some joints on these cars run without gaskets; where a gasket or spring pack is used, renew it rather than winding a nut down onto a shoulder until the stud snaps.

Copper anti-seize on the studs helps the next owner. Keep fresh pipe clear of the floor and fuel tank. Drop a shield only as far as you need for access; some shields overlap and force you to loosen the neighbour first.