Front exhaust pipe with catalytic converter
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Front exhaust pipe with catalytic converter
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Important
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The exhaust pipe's flexible section is highly sensitive to bending and must not be bent more than about 5°, as this could result in permanent deformation.
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Do
not
allow the catalytic converter to hang from the flexible section.
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1.
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Remove the heat shield over the exhaust manifold.
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2.
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Unplug the oxygen sensor's leads, undo the clip and cable clamps.
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Important
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The leads must not be twisted. The oxygen sensor is sensitive to knocks and blows and must be handled with care.
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3.
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Unscrew the upper nuts at the joint between exhaust manifold and front exhaust pipe. Raise the car.
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4.
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Remove the oxygen sensor.
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5.
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Loosen the joint between the front exhaust pipe and the middle pipe.
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6.
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Undo the remaining nuts at the joint between the front exhaust pipe and exhaust manifold.
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7.
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Remove the two rubber mountings between the catalytic converter and engine subframe
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8.
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Lower the front exhaust pipe.
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Important
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The exhaust pipe's flexible section is highly sensitive to bending and must not be bent more than about 5°, as this could result in permanent deformation.
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Do
not
allow the catalytic converter to hang from the flexible section.
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2.
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Fit the rubber mountings between the catalytic converter and engine subframe. If necessary, change the rubber bushes.
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3.
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Position the front exhaust pipe and secure it to the exhaust manifold by means of the two lower nuts.
Tightening torque: 40 Nm (30 lbf ft)
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4.
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Bolt the front exhaust pipe and intermediate pipe together, using a new clamp.
Tightening torque: 20 Nm (15 lbf ft)
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Important
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To avoid leakage, use new clamps when tightening the joints.
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Make sure that there is adequate clearance to parts next to the exhaust system.
Also check that the rear silencer's tailpipe is correctly positioned in the opening that is cut out for it in the rear bumper.
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5.
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Fit the oxygen sensor, but first lubricate the threads with Molycote 1000, part No. 30 20 971.
Tightening torque: 55 Nm (41 lbf ft)
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Important
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The oxygen sensor is sensitive to knocks and blows and must be handled with care. It is important to ensure that the connection between it and the nipple is gastight.
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The oxygen sensor's lead must not be stretched between engine and exhaust pipe. Secure the cable to the clips so that a loop is formed just before the sensor.
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6.
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Lower the car to the floor.
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7.
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Screw on the upper nuts securing the front exhaust pipe to the exhaust manifold and tighten them.
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8.
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Plug in the oxygen sensor's leads and fit the clip and cable clamps.
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9.
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Fit the heat shield over the exhaust manifold.
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