Front exhaust pipe with catalytic converter B205L/R, B235R
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Front exhaust pipe with catalytic converter B205L/R, B235R
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When changing the front exhaust pipe, the oxygen sensors must be removed and fitted to the new exhaust pipe. Apply Molykote 1000, part no. 30 20 971 to the threads on the oxygen sensors before fitting.
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Important
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The leads of the oxygen sensors must not be twisted. Twisted leads are susceptible to vibration and the leads could break.
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Since the oxygen sensors are sensitive to impact and shock, they must be handled with care.
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Tightening torque: 55 Nm ( lbf ft)
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1.
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Remove the bypass pipe with valve. Keep the O-ring where the pipe is connected to the turbo inlet pipe.
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2.
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Remove the exhaust manifold heat shield and the top engine cover.
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3.
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Unplug the oxygen sensor connectors.
Cut the cable tie securing the oxygen sensor cables and adjust their position so that they run free when the pipe is removed.
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4.
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Undo the 2 upper nuts on the joint between the turbocharger and the front exhaust pipe.
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6.
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Undo the lower nut on the joint between the turbocharger and the front exhaust pipe as well as the bolt on the catalytic converter brace.
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7.
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Remove the clamp at the joint between the front exhaust pipe and the intermediate pipe.
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8.
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Unhook the exhaust pipe from its rubber mountings and lower it away. Make sure that the leads of the oxygen sensors are not caught up or damaged when the exhaust pipe is removed.
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Important
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The flexible section in the front part of the exhaust pipe must not be bent more than 5°.
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Important
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The flexible section of the exhaust pipe is sensitive to bending and must not be angled more than 5° as this could lead to 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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Clean the joints.
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2.
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Offer up the exhaust pipe and hook it onto its rubber mountings. If necessary, change the rubber bushes.
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3.
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Fit the lower nut between the front exhaust pipe and the turbocharger. Smear the threads with Molycote 1000, part no. 30 20 971, or the equivalent.
Tightening torque 25 Nm (19 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 30 Nm (22 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.
Check that the tailpipe is positioned symmetrically in the space cut out for it in the rear bumper.
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5.
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Fit the catalytic converter brace and oxygen sensor cables. Lower the car.
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6.
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Fit the upper nuts between the front exhaust pipe and the turbocharger. Coat the threads with Molycote 1000, part no. 30 20 971, or the equivalent.
Tightening torque: 25 Nm (19 lbf ft)
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Important
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Tighten the nuts alternately to avoid misalignment of the flange. The exhaust pipe flange must not abut against the turbocharger flange.
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7.
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Run the oxygen cables forward and plug in the connector. Secure the cables with a cable tie.
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Important
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The oxygen sensor's leads must not be twisted.
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Make sure that the lead does not rest against hot surfaces or sharp edges.
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8.
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Fit the exhaust manifold's heat shield.
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9.
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Fit the bypass pipe with valve. Lubricate the O-ring at the connection to the turbo inlet pipe with non-acidic vaseline, part no. 30 06 665, or the equivalent.
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10.
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Fit the top engine cover
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