Front exhaust pipe with catalytic converter (B204L/E/R)
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Front exhaust pipe with catalytic converter (B204L/E/R)
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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 the upper cable clamp.
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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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Remove the lower cable clamp and oxygen sensor.
Raise the car.
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4.
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Loosen the joint between the front exhaust pipe and the middle pipe.
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5.
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Unscrew the front exhaust pipe from the turbocharger.
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6.
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Detach the exhaust pipe from the rubber mounting on the engine subframe and lower the exhaust pipe.
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2.
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Position the front exhaust pipe and secure it to the turbocharger. Before fitting, lubricate the three studs on the turbocharger with Molycote 1000, part No. 30 20 971.
Tightening torque: 25 Nm (18.5 lbf ft)
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3.
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Attach the exhaust pipe to the engine subframe with the rubber mountings from the catalytic converter. If necessary, use new rubber bushes.
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4.
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Screw together the joint at the intermediate pipe, 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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5.
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Lower the car to the floor.
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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Run the cable up, connect it and fit the connector in the holder.
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Important
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Watch out for sharp edges and hot components.
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Secure the cable to the turbo's coolant pipe, using a cable tie.
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7.
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Fit the heat shield over the exhaust manifold.
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