This tutorial is also available in French
➔
Exhaust system change on Austin Mini
Vehicle ➔ Mini 1000 am1991 automatic gearbox
Difficulty ➔ Medium
Time ➔ 3 hours
Summary
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Originally, the exhaust system (GEX177) was in one piece. Nowadays, to facilitate packaging and reduce transport costs, it is in 2 parts.
The exhaust system (GEX177) is supplied with the central clamp (GEX7052), the front clamp (GEX7053) and the central flange.
The rubbers of the silent blocks supporting the exhaust system eventually crack over time. The silent blocks are then weakened and eventually break. At the slightest doubt, do not hesitate to change them.
When screwing the exhaust bolts and studs, put a little copper grease on the threads. This will limit oxidation and facilitate unscrewing during the next disassembly.
The installation of the exhaust system requires one person under the car to hold the system and one person above to position the manifold flange. Get help from a friend, it will be much easier.
Required Tools
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Packaging :
•
GEX177: The exhaust system consists of the downpipe (front part), the silencer (rear part), the central clamp (GEX7052), the front clamp (GEX7053) and the central flange.
• GEX7052, GEX7053: These parts are supplied with the exhaust system. No need to order them.
• All other parts above are sold individually.
• GEX7052, GEX7053: These parts are supplied with the exhaust system. No need to order them.
• All other parts above are sold individually.
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Remove the exhaust system
Op 01
Remove the air filter housing (➔ see tutorial ''Replacing the HS4 Air Filter'' Op 01 to 02).
Op 02
Disconnect the throttle cable from the carburetor (➔ see tutorial ''Replacing the Throttle Cable'' Op 02 to 04).
Op 03
Remove the carburetor (➔ see tutorial ''Removing the HS4 Carburetor'' Op 03 to 12).
Op 04
Unscrew the exhaust manifold flange. Use the 13 mm socket.
Do not hesitate to spray penetrating oil on the flange fixing bolts as they are very often oxidized.
Op 05
Remove the exhaust manifold flange.
Op 06
Unscrew the fixing nut of the front exhaust clamp. Use the 13 mm socket.
Remove the bolt and washers.
Op 07
Unscrew the fixing nut of the central exhaust bracket. Use the 13 mm socket.
Do not take into account the bracket that you discover on the photos above. The previous owner of the Mini had apparently tinkered with a homemade bracket.
Op 08
Unscrew the fixing nut of the rear exhaust clamp. Use the 13 mm combination spanner.
Op 09
Remove the exhaust system. Remove it from under the vehicle.
Op 10
Unscrew the fixing nut of the rear silent block of the exhaust system. Use the 13 mm socket.
Remove the rear silent block.
Op 11
Unscrew the 2 fixing bolts of the central silent block of the exhaust system. Use the 13 mm socket.
Remove the central silent block.
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Reinstall the exhaust system
Op 12
Fit the rear silent block (GEX7251), the spring washer (GFK1125) and tighten the nut (GFK3212). Use the 13 mm socket.
Op 13
Fit the central silent block (GEX7081), the 2 spring washers (GFK1125) and tighten the 2 bolts (GFK5184). Use the 13 mm socket.
Op 14
Fit the central bracket (GEX7082), the spring washer (GFK1125) and the nut (GFK3212).
Do not tighten the nut for now.
Op 15
Fit the front clamp (GEX7053) approximately on the front part of the exhaust system.
Op 16
Fit the rear clamp (GEX7084), the central clamp (GEX7052) and the central flange approximately on the rear part of the exhaust system.
Use a large flathead screwdriver to slightly widen the rear clamp when placing it on the exhaust pipe. This will facilitate sliding.
Do not position the fixing bolts of the clamps and do not tighten the fixing nuts of the flange for now.
Op 17
Perfectly clean the outlet of the exhaust manifold. Use abrasive paper.
Op 18
Fit the front part of the exhaust system on the vehicle.
Check that the collar of the exhaust system applies perfectly to the manifold outlet.
Take the time to check that the exhaust system can be perfectly positioned on the manifold. It's really not cool to discover that there is a leak when starting the vehicle when everything has been reassembled.
Op 19
Apply Firegum to the collar of the exhaust system. This will improve sealing.
Firegum is not essential when installing the exhaust system. Nevertheless, it is a cheap product that works wonders.
Op 20
Fit the exhaust system on the manifold and install the flange (GEX7046).
Tighten moderately. Use the 13 mm socket.
It is at this moment that the help of an additional person is necessary. To maintain the exhaust system during the installation of the flange.
At this stage of reassembly, it is preferable not to block the flange and leave a small angular freedom at the level of the exhaust system coupling with the manifold. This will facilitate the following operations.
Op 21
From under the vehicle, check that the collar of the exhaust system is well taken in the flange over its entire periphery.
Op 22
Fix the front clamp (GEX7053) on its support bracket with a bolt (GFK5184), a washer (GFK1114), a washer (GFK1125) and a nut (GFK3212).
Do not tighten the nut for now.
Op 23
Check that the downpipe of the exhaust system does not come into contact with either the transmission driveshaft or the vehicle body.
Op 24
Fit the rear part of the exhaust system on the vehicle.
Engage the front part of the exhaust system in the rear part.
Also apply Firegum to the pipes at the junction of the 2 parts of the exhaust system. This will improve sealing.
Op 25
Fix the central clamp on the support bracket with a bolt (GFK5185), a washer (GFK1125) and a nut (GFK3212).
Do not tighten the bolt for now.
Op 26
Fix the rear clamp (GEX7084) to the silent block with a washer (GFK1125) and a nut (GFK3212).
Do not tighten the nut for now.
Op 27
Fit the central flange and tighten the nuts slightly.
Op 28
Add a tightening bolt (GFK5185) on the front clamp with a washer (GFK1125) and a nut (GFK3212).
Op 29
Add a tightening bolt (GFK5185) on the rear clamp with a washer (GFK1125) and a nut (GFK3212).
Op 30
Check that the exhaust system is well positioned and that it does not touch the bodywork.
Op 31
All that remains is to tighten the 2 nuts of the manifold flange, the 2 nuts of the front clamp, the 2 nuts of the central flange, the 2 nuts of the central clamp and the 2 nuts of the rear clamp. Use the 13 mm combination spanner and the 13 mm socket.
Op 32
Fit the carburetor on the intake manifold (➔ see tutorial ''Removing the HS4 Carburetor'' Op 13 to 26).
Op 33
Connect the throttle cable to the carburetor (➔ see tutorial ''Replacing the Throttle Cable'' Op 30 to 34).
Op 34
Check the carburetor oil level (➔ see tutorial ''Removing the HS4 Carburetor'' Op 28 to 29).
Op 35
Reinstall the air filter housing (➔ see tutorial ''Replacing the HS4 Air Filter'' Op 10 to 13).
The End
