49-100 Removing and installing exhaust system
Preceding work: Removing and installing engine compartment panelling. | Operation No. of operation texts and work units or standard texts and flat rates: 49-0170 |
Shown on Model 124
Exhaust system as of plug connection | remove, replace and bolt together, install |
Oxygen sensor (G3/2) from front exhaust |
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Pipe shackle (6) with Belleville spring washers (17) and self-locking nuts (23) |
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Bolts (4a) | unscrew, screw in. Replace bolts (4). |
Supporting bracket (10 or 10a) with bolts (11), |
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Front exhaust pipe with catalytic converter (2a) |
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Rivet nuts (1) | at exhaust manifold, remove, install. of caulking bolt 30 Nm. |
Exhaust system | check for leaks with engine running. |
Special tools
Install the Belleville spring washers at the pipe shackle so that the concave faces stand off from each other (as shown in illustration).
Plug connections of oxygen sensor in front of front right seat (if oxygen sensor screwed into front exhaust pipe).
Note
Engine 102.96/98 KAT as of 09/89 oxygen sensor in exhaust manifold.
G3/2x1 Oxygen sensor heating coil plug connection
G3/2x2 Oxygen sensor signal plug connection
Knock rivet nuts out of the holes in the exhaust manifold with a suitable bolt. Screw in bolt by hand only.
Insert new rivet nut into hole of exhaust manifold. Screw in caulking bolt and tighten to a torque of 30 Nm.
Model 201 with engine 102.962/985 KAT
As part of our policy of continuous technical development, engines of a higher output have been installed in the above models. The uprated engine output is achieved as a result of a modified exhaust system.
Two-pipe between catalytic converter or front silencer and center silencer.
Pipe diameter of 55 mm (was 48 mm) between center and tail silencer.
Volume of center silencer enlarged.
Production breakpoint: 12/90
Model | Engine | Vehicle ident |
201.024 201.028 | 102.962 102.985 | A 608776 F 814353 A 608776 F 814353 |
A Previous version
B Present version
The exhaust system is not intended for retrofitting.
Model 201 with engine 102.910
KAT version
Reduced catalytic converter (9")
Insulation upstream of KAT
Center and tail silencer with modified internal design
Straight tail pipe bent downward
Front exhaust system with pre-catalytic converters
Front exhaust system with resonators
Version without KAT
Front exhaust system with pre-catalytic converters
Rear system with center and tail silencer identical to KAT version, see above
1991 Model 201 with engine 102.985
Pre-catalytic converters omitted.
Insulation upstream of KAT.
Catalytic converter enlarged (11").
Suspended upstream of catalytic converter.
Model 201.036 with engine 102.992
Pre-catalytic converters omitted.
Two-channel up to approx. 150 mm downstream of exhaust manifold.
Tail silencer adapted to engine output, and also improved in terms of noise. Recognizable from fitting of additional outlet extension.
The underfloor catalytic converter is designed as a steel monolith (two-channel, 2x2x3"). The number of cells has been reduced to 200/inch, but increased in the cross-section.