Next detach the lambda sensor from the exhaust, if you have a Mk1 to
Mk3 you wont have a second sensor on the exhaust.
To remove the sensor (Mk4 onwards) follow the cable up from the lambda sensor and unhook
the plug from its bracket and unplug the sensor.
Use a 22mm ring spanner to
unscrew the lambda sensor from the exhaust. These sensors are often
difficult to remove due to the heat they are subjected to, so some
‘gentle’ persuasion may be required.
The next job is to remove the
turbo studs. Use a 13mm socket to undo the studs (green arrows)
Be careful when doing this as
these studs are known to snap in the turbo. If they do the studs
will need extracting.
(To improve access, you can remove the bolt securing the heat shield
(blue arrow) around the turbo mounted lambda sensor, and lift the
heat shield. )
Undo the exhaust bracket from
the gearbox. It will be mounted by 2 E14 bolts (red arrows). The
exhaust should now come away from the car.
Take the new exhaust and fit
the lambda sensor. Take a new pair of turbo studs and screw onto the
turbo. Note that should also use new turbo studs when changing the
exhaust. If you look closely at the replacements, the brass nuts are
slightly oval. They deform as you turn them onto the stud making
them a one time fit!
Bring the new exhaust up into
position and attach on it mountings. Some exhausts also provide an
additional mounting bracket which bolts onto the gearbox using same
bolts used by the bracket for the turbo inlet pipe.
Ensure the exhaust fits nicely
onto the turbo. Do up the mounting bolts firmly, but not tight. Put
the nuts onto the turbo studs and tighten firmly.
Tighten the remaining exhaust mounting brackets.
Plug the lambda sensor back
in, and run the engine to check the exhaust is suitably mounted with
no signs of leakage.
If all is good then replace the rear crash bar and rear panel.