Front exhaust system with catalytic converters, B235E/R
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Front exhaust system with catalytic converters, B235E/R
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1.
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Remove the exhaust manifold's heat shield.
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2.
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Unplug the connectors to the oxygen sensors. Cut off the cable tie and pull out the cables.
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3.
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Loosen the two upper nuts at the connection between the turbo/front exhaust system.
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5.
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Loosen the third nut at the connection between the turbo/front exhaust system.
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6.
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Remove the screws from the bar holding the catalytic converter to the engine.
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7.
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Separate the pipe joint between the front and rear exhaust systems.
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8.
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Remove the clips and carefully pull away the rubber mountings
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9.
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Lower the front exhaust system.
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Important
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The flexible section at the front of the exhaust system should not be bent out of line by more than 5°, i.e. if the front exhaust system is allowed to hang, it must not bend more than the sag caused by its own weight.
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If the pipe is overloaded, permanent deformation of the components will result. This can cause noise and leakage, and damage at a later stage.
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10.
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Remove the oxygen sensors
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Important
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When fitting the front exhaust system to the turbo, the nuts should be tightened alternately to avoid distorting the flange. The flange must not abut against the turbo connection flange.
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Ensure that the system hangs straight so that no stresses occur during fitting.
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Note
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Coat the studs sparingly with Molycote 1000, part no. 30 20 971 or similar.
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1.
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Mount the oxygen sensors on the catalytic converter
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2.
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Fit the front pipe with rubber mountings and clips.
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3.
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Fit the nuts on the rear pipe joints.
Tightening torque 22 Nm (16 lbf ft)
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4.
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Fit the lower nut on the turbocharger.
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5.
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Fit the screws holding the catalytic converter to the engine.
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6.
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Lift up the oxygen sensor cables and lower the car.
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7.
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Fit the two upper nuts on the exhaust system.
Tightening torque 24 Nm (18 lbf ft)
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8.
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Lay out the oxygen sensor cables and plug in the connectors.
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9.
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Secure the cables with a cable tie.
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10.
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Fit the heat shield over the exhaust manifold
Tightening torque, nut, heat shield 20 Nm (15 lbf ft)
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