Replacing Intermediate Pipes With Catalytic Converter

Removing And Installing Intermediate Pipe With Catalytic Converter

Warning: Scalding hazard!

Only perform these tasks after exhaust system has cooled down.
Remove underbody protection.

US version:
Front pipes are fitted in place of the ECE catalytic converter.





ECE version:
Release screws.
Unclip both plug connections (1) and disconnect.

Note: Plastic holder with both cables of monitor sensors is removed with catalytic converter.





Release nut.
Remove holder (1).
Unclip plug connection (2) and disconnect.





Release screw connection of flanges at exhaust manifold.

Installation:
Check seals and replace if necessary.
Replace self-locking nuts and screws.
Coat thread with copper paste.

Preliminary tightening:
Tighten screws alternately to locate relevant flange pair.
Final tightening:
Tighten screws to specified tightening torque, refer to Specifications.





Release nuts.
Remove air deflector (1).





Support exhaust system with jack and special tool 31 2 220 and secure against falling out.





Release screws (1).
Remove reinforcement plate (2).
Release screws (3).
Reinforcement plate (4) remains connected by means of 2 rubber mounts to exhaust system.





Release screws and remove body reinforcement strut (1).

Caution: A 2nd person is essential to help ensure safe removal of the exhaust system.





Release screw connection of flanges between rear muffler and intermediate pipes.

Installation:
Check seal, replace if necessary.
Remove intermediate pipe with catalytic converter.