Removing and Installing Exhaust System
Removing and Installing Exhaust System
Preceding work:
Removing and installing engine compartment panel
Removing and installing, replacing and bolting exhaust system as of plug connection (49-7280). Removing, Installing, Replacing and Bolting Exhaust System As of Plug Connection
A. Model 107
Separate plug connection, oxygen sensor heating coil (G3/2x1) and plug connection, oxygen sensor signal (G3/2x2), in right footwell, below cover plate.
Pull off heat shield (2c). Pay attention to installation position.
Unscrew oxygen sensor (G3/2).
Installation note: Coat thread with paste 000 989 88 51. Ensure the cable is correctly routed.
Unscrew bolts (27). Take off flame shield (28) (only (J)).
Unscrew bolts (4). Replace bolts (4). Tightening torque 25 Nm.
Detach rubber rings (18, 29). Check whether damaged and worn.
Take off front exhaust pipe with front and underflow catalytic converter (2a) or front exhaust pipe with front and centre silencer (2g)
Remove riveted nuts (1) at exhaust manifold. Knock out riveted nuts with a suitable tool, (e.g. bolt).
Installation note: Install riveted nuts with cocking bolt 103 589 01 39 00. Tightening torque of cocking bolt 30 Nm (reference value).
Check carrier (10) suitability for reuse, replace if necessary.
Check exhaust system for leaks with engine running.
Special Tools:
Location Of Oxygen Sensor Plug Connection:
B. Models 124, 126, 201
Separate plug connection, oxygen sensor heating coil (G3/2x1) and plug connection, oxygen sensor signal (G3/2x2), in footwell.
Pull off heat shield (2c). Pay attention to installation position.
Unscrew oxygen sensor (G3/2).
Installation note: Coat thread with paste 000 989 88 51. Ensure the cable is correctly routed.
Take off retaining bar (31) with dished springs (32) and self-locking nuts (33). Tightening torque 7 Nm (reference value).
Installation note: Check parts and replace if necessary.
Caution! Pay attention to illustration note for installing dished springs.
Unscrew bolts (4). Replace bolts (4). Tightening torque 25 Nm.
Take off carrier (30) with bolts (11), washers (12), rubber washers (14) and nuts (23). Tightening torque 20 Nm (reference value).
Installation note: Check parts and replace if necessary.
Take off front exhaust pipe with front and underflow catalytic converter (2a) or front exhaust pipe with silencer (2).
Remove riveted nuts (1) at exhaust manifold. Knock out riveted nuts with a suitable tool, (e.g. bolt).
Installation note: Install riveted nuts with cocking bolt 103 589 01 39 00. Tightening torque of cocking bolt 30 Nm (reference value).
Check exhaust system for leaks with engine running.
Special Tools:
Caution! Install the dished springs at the retaining bar so that the curved face is always opposite the other (as illustrated).
Model 124:
Model 126:
Model 201 - 1st Version:
Model 201 - 2nd Version:
C. Model 129
Separate plug connection, heated oxygen sensor heating (G3/2x1), at outside right of transmission tunnel.
Note:
Slackening union nut = counter-clockwise
Tightening union nut = clockwise
Pull off heat shield (2c). Pay attention to installation position.
Unscrew oxygen sensor (G3/2).
Installation note: Coat thread with paste 000 989 88 51. Ensure the cable is correctly routed.
Unscrew self-locking nuts (6a), replace. Tightening torque 20 Nm (reference value).
Take off carrier (30) with bolts (11), washers (12), rubber washers (14) and nuts (23). Tightening torque 20 Nm (reference value).
Installation note: Check parts and replace if necessary.
Check suitability of threaded plate (6) for reuse, replace if necessary.
Unscrew bolts (4). Replace bolts (4). Tightening torque 23 Nm (reference value).
Detach rubber ring (17). Check for damage and wear.
Take off front exhaust pipe with front and underflow catalytic converter (2a) or front exhaust pipe with front silencer (2b).
Replace bolt (16). Tightening torque 25 Nm (reference value).
Check suitability of holder (15) for reuse.
Remove riveted nuts (1) at exhaust manifold. Knock out riveted nuts with a suitable tool, (e.g. bolt).
Installation note: Install riveted nuts with cocking bolt 103 589 01 39 00. Tightening torque of cocking bolt 30 Nm (reference value).
Check exhaust system for leaks with engine running.
Special Tools:
