Front exhaust system with catalytic converter, 4-cyl. B205E
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Front exhaust system with catalytic converter, 4-cyl. B205E
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1.
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Remove the bypass pipe and valve (C).
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Note
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There is an O-ring on the bypass pipe attachment to the turbo intake pipe.
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2.
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Remove the exhaust manifold heat shield (B).
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3.
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Remove the oxygen sensor (A).
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4.
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Undo the two upper nuts securing the joint between the turbocharger and front exhaust system (D).
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6.
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Remove the lower front cover (A).
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7.
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Undo the third nut holding the turbocharger and front exhaust system (E) together.
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8.
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Undo the pipe joint between the front and rear exhaust systems (C).
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9.
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Remove the clips from the rubber mountings (B).
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10.
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Carefully withdraw the rubber mountings (A).
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11.
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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 7°, 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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Note
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Coat the studs sparingly with Molycote 1000, part no. 30 20 971 or similar.
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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 7°, 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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1.
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Raise the front part of the exhaust system.
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2.
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Fit the third nut holding the turbocharger and front exhaust system (E) together.
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3.
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Fit the rubber mountings (A).
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4.
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Fit the clips on the rubber mountings (B).
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5.
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Fit the pipe joint between the front and rear exhaust systems and fit the nuts (C).
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6.
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Fit the two upper nuts securing the joint between the turbocharger and front exhaust system (D).
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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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7.
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Tighten the nuts to the prescribe tightening torque:
Turbo/front exhaust pipe: 24 Nm (17.7 lbf ft)
Front/rear exhaust system: 22 Nm (16.2 lbf ft)
Bypass pipe/intake pipe: 8 Nm (5.9 lbf ft)
Bypass pipe, hose clip: 8 Nm (5.9 lbf ft)
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8.
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Fit the lower front cover (A).
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9.
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Fit the oxygen sensor (A).
Tightening torque, oxygen sensor 55 Nm (40.5 lbf ft)
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10.
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Fit the exhaust manifold heat shield (B).
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Note
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There is an O-ring on the bypass pipe attachment to the turbo intake pipe.
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11.
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Fit the bypass pipe and valve (C).
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