remove the air cleaner (see Part A of this
Chapter) and detach the throttle return spring
from the bracket on the exhaust manifold
clamp.
2 Undo and remove the nuts and bolts and
withdraw the manifold clamp (see
illustration).
3 Position the car over an inspection pit, or
alternatively jack it up and support it on axle
stands (see “Jacking and vehicle support”).
4 From underneath the car, undo and remove
the nut and bolt securing the exhaust front
pipe to the transmission or transmission
bracket.
5 Now undo and remove the nuts and spring
washers securing the exhaust intermediate
and rear mounting brackets to the rubber
blocks on the rear subframe. Slide the
brackets off the studs on the rubber blocks
and lower the complete system to the ground.
6 Carefully inspect the rubber mounting
blocks, the exhaust system brackets and
clamps for signs of deterioration, corrosion or
damage and renew as necessary.
Refitting
7 To refit the exhaust system, place it in
position under the car and locate the brackets
onto the rubber mounting blocks at the rear.
Refit the nuts and spring washers but do not
tighten at this stage.
8 Before positioning the bellmouth of the
front pipe over the manifold flange, smear its
mating surface with sealing paste. Doing this
will obviate any risk of leakage. With the help
of an assistant, locate the bellmouth squarely
over the flange on the manifold. Hold the
system in this position and refit the manifold
clamp. Ensure that the pipe is square and that
the clamp is seated properly over the pipe
and manifold flanges otherwise leaks will
occur at this joint.
9 Now fully tighten the manifold clamp
securing bolts and refit the throttle return
spring.
10 Check that the exhaust system is clear of
the subframe and floor pan over its entire
length and that it is not in tension. Now fully
tighten the rear mountings.
11 Lower the car to the ground, refit the air
cleaner, start the engine and check for leaks.
Cooper S models
Removal
12 Position the car over an inspection pit, or
alternatively jack it up and support it on axle
stands (see “Jacking and vehicle support”).
13 If the rear silencer and tailpipe only are to
be removed, slacken the exhaust clamp
securing the rear silencer to the front pipe and
then remove the retaining clip securing the
tailpipe to the rear mounting. Twist the rear
silencer back and forth to separate the joint and
then withdraw the tailpipe from under the car.
14 To remove the complete system, slacken
the front pipe to exhaust manifold clamp, and
undo and remove the bolts securing the rear
mountings to the subframe. Twist the
complete system back and forth to free the
joint and lower it to the ground.
Refitting
15 In all cases, refitting is the reverse of
removal.
3 Exhaust system (models
with catalytic converter) -
removal and refitting
1
Tailpipe and silencer
Removal
1 Position the car over an inspection pit, or
alternatively jack it up and support it on axle
stands (see “Jacking and vehicle support”).
2 Slacken and remove the two nuts securing
the tailpipe flange to the catalytic converter
studs (see illustration).
3 Either slacken and remove the nuts and
bolts securing the tailpipe and silencer to its
mounting brackets, or release it from its
mounting rubbers (as applicable), then
withdraw the assembly from underneath the
car and recover the flange gasket.
Refitting
4 Refitting is the reverse sequence to
removal, ensuring that the flange mating
surfaces are clean and free of corrosion, and
using a new gasket.
Catalytic converter
Removal
5 Remove the tailpipe and silencer assembly
as described above.
6 Unscrew the two nuts securing the catalytic
converter to the front pipe, then withdraw the
catalytic converter from underneath the car
and recover the flange gasket.
Refitting
7 Refitting is the reverse sequence to
removal, ensuring that the flange mating
surfaces are clean and free of corrosion and
using new gaskets.
Front pipe
Removal
8 On carburettor models, remove the air
cleaner assembly (see Part A of this Chapter).
9 Position the car over an inspection pit, or
alternatively jack it up and support it on axle
stands (see “Jacking and vehicle support”).
10 Slacken and remove the two nuts
securing the catalytic converter to the front
pipe. Unscrew the nut and bolt securing the
front pipe to the bracket on the transmission.
11 On Cooper models, undo the gas
sampling pipe mounting bolts, then slacken
its union nut and remove the pipe from the
side of the exhaust front pipe.
12 On all carburettor models, unbolt the
exhaust front pipe-to-manifold clamp(s), then
remove the front pipe from underneath the
car, and recover the flange gasket from the
catalytic converter.
13 On fuel injection models, undo the three
nuts securing the front pipe to the exhaust
manifold, then release the pipe from the
manifold and catalytic converter studs.
Remove the front pipe from underneath the
car, and recover the flange gaskets.
Refitting
14 Refitting is the reverse sequence to
removal, ensuring that the mating surfaces of
the exhaust system are clean and free from
corrosion. Fit a new gasket to the catalytic
converter flange, and apply a smear of sealing
paste to the front pipe-to-manifold joint, to
alleviate any risk of leakage.
4 Exhaust manifold - removal
and refitting
3
Carburettor models except
Cooper S
1 The exhaust manifold fitted to all
carburettor models except Cooper S is
removed as an assembly with the inlet
manifold. Full details on this procedure will be
found in Part A of this Chapter.
Cooper S carburettor models
Removal
2 Remove the carburettors and inlet manifold
as described in Part A of this Chapter.
3 Remove the complete exhaust system as
described in Section 2 of this Part.
4 Undo and remove the nuts and flat washers
securing the manifold to the cylinder head
studs. Now ease the manifold off the studs
and carefully manipulate it out of the engine
compartment.
5 Before removing the LCB (long centre
branch) exhaust manifold, refer to Chapter 8
and detach the right-hand driveshaft at the
inboard end.
6 Refer to Chapter 10 and remove the right-
hand front roadwheel, disconnect the steering
tie-rod, the swivel hub at its upper and lower
points, and partially withdraw the hub and
driveshaft. Do not allow the assembly to hang
from the brake hose.
7 Turn the differential driving flange so that it
is upright. Release the exhaust manifold from
the cylinder head, manoeuvre it to the right to
clear the subframe and transmission casing
before easing it upwards.
Refitting
4C•4 Exhaust and emission control systems
Position a jack under the
exhaust front pipe and raise
it just sufficiently to hold the
bellmouth tightly against the manifold
flange. This will ensure that the joint is
properly seated as the clamp is fitted.
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