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 oxygen sensor connectors. Cut 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) (up to and including engine no. 7011078)
Tightening torque, nut, heat shield 21 Nm (16 lbf ft) (from and including engine no. 7011079)
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