Remove / install catalytic converter and front exhaust system

AR49.10-P-5531AC

Remove / install catalytic converter and front exhaust system

27.6.07

 

Remove/install

Danger!

Risk of death caused by vehicle slipping or toppling off the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



For vehicles with code P98 Black Series the flange connection (7) is located on the right catalytic converter (1b) and for vehicles without code P98 Black Series on the left catalytic converter (1a)

1

Lift vehicle on lifting platform.

AR00.60-P-1000P

2

Remove bottom engine compartment paneling

AR61.20-P-1105P

Left catalytic converter (1a)

3

Disconnect connector of left O2 sensor, upstream of TWC (G3/3x1)

 Remove connector from brackets.

4

Disconnect connector of left O2 sensor, downstream of TWC (G3/5x1)

 Remove connector from brackets.

5

Remove left catalytic converter (1a) at exhaust manifold

 Installation: Replace bolts (2) since the connection may loosen or the bolts may shear off if they are used again. Check rivet nuts in the exhaust manifold and replace them if required: 

Replace rivet nuts in exhaust manifold.

AR49.10-P-5531-01DA

 Model 203.076/ 276, 209.376

*BA14.10-P-1002-01B

 Model 209.377 /477

*BA14.10-P-1002-01N



*103589013900

6

Remove bracket (3) for exhaust system on transmission by removing bolts (4)



*BA49.10-P-1007-01A

7

Support left catalytic converter (1a)

8.1

Disconnect flange connection (7) on left catalytic converter (1a)

Vehicles without code P98 Black Series

 Installation: Replace bolts (9) and nuts (10) because the connection may not be tight and the bolts may shear off if they are reused.

 Installation: Check seal ring (8) for damage and replace it if required. Clean connecting points of combustion and corrosion residues.



*BA49.10-P-1009-01A

8.2

Disconnect catalytic converter, left (1a) on exhaust clamp (13)

Vehicles with code P98 Black Series

 Installation: Check the exhaust clamp (13) for damage and replace it if required. Clean connecting points of the exhaust pipe free of combustion and corrosion residues.



*BA49.10-P-1008-01A

9

Disconnect flange connection on catalytic converter, right (1b)

Vehicles with code P98 Black Series

 Installation: Replace bolts (9) and nuts (10) because the connection may not be tight and the bolts may shear off if they are reused.

 Installation: Check seal ring (8) for damage and replace it if required. Clean connecting points of combustion and corrosion residues.



*BA49.10-P-1009-01A

10

Lever out left catalytic converter (1a)

 When levering out ensure that the O2 left sensor upstream of the catalytic converter and the O2 left sensor downstream of the catalytic converter are not damaged.

 Installation: Clean connecting points free of combustion and corrosion residues.



Notes on disposing of catalytic converters

OS49.10-P-1000-01A

Right catalytic converter (1b)

11

Unplug connector for right O2 sensor upstream of TWC (G3/4x1)

 Remove connector from brackets.

12

Disconnect connector of right O2 sensor upstream of TWC (G3/6x1)

 Remove connector from brackets.

13

Detach right catalytic converter (1b) at exhaust manifold

 Installation: Replace bolts (2) since the connection may loosen or the bolts may shear off if they are used again. Check rivet nuts in the exhaust manifold and replace them if required: 

Replace rivet nuts in exhaust manifold.

AR49.10-P-5531-01DA

 Model 203.076/ 276, 209.376

*BA14.10-P-1002-01B

 Model 209.377 /477

*BA14.10-P-1002-01N



*103589013900

14

Remove bracket (3) for exhaust system on transmission by removing bolts (4)



*BA49.10-P-1007-01A

15

Support right catalytic converter (1b)

16

Disconnect flange connection (7) on left catalytic converter (1a)

Vehicles without code P98 Black Series

 Installation: Replace bolts (9) and nuts (10) because the connection may not be tight and the bolts may shear off if they are reused.

 Installation: Check the seal ring (8) for damage and replace it if required. Clean connecting points of combustion and corrosion residues.



*BA49.10-P-1009-01A

17.1

Disconnect right catalytic converter (1b) at exhaust clamp (13)

Vehicles without code P98 Black Series

 Installation: Check exhaust clamp (13) for damage and replace it if required. Clean connecting points of the exhaust pipe free of combustion and corrosion residues.



*BA49.10-P-1008-01A

17.2

Disconnect flange connection on catalytic converter, right (1b)

Vehicles with code P98 Black Series

 Installation: Replace bolts (9) and nuts (10) because the connection may not be tight and the bolts may shear off if they are reused.

 Installation: Check seal ring (8) for damage and replace it if required. Clean connecting points of combustion and corrosion residues.



*BA49.10-P-1009-01A

18

Lift out right catalytic converter (1b)

 When levering out ensure that the O2 right sensor upstream of the catalytic converter and the O2 right sensor downstream of the catalytic converter are not damaged.



*BA49.10-P-1009-01A



Notes on disposing of catalytic converters

OS49.10-P-1000-01A

19

Install in the reverse order

20

Check installation position and clearance of exhaust system

 The exhaust system must be mounted free of tension, align exhaust system if required.

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

21

Test run engine and check exhaust system for leaks

Number

Designation

Engine 113.987/
988/990/
991

BA14.10-P-1002-01B

Flange connection, exhaust manifold/front exhaust pipes

Nm

20

Number

Designation

Engine
156

BA14.10-P-1002-01N

Flange connection for exhaust manifold/front exhaust pipe

Nm

20

Number

Designation

Engine
112, 113
in model
203

Engine
112, 113
in model
209

Engine
156
in model
209

BA49.10-P-1007-01A

Bolt, exhaust bracket to transmission

Nm

20

20

20

BA49.10-P-1008-01A

Self-locking nut to front exhaust pipe

Nm

20

20

-

BA49.10-P-1009-01A

Bolt, flange connection to exhaust pipe/exhaust manifold

Nm

20

20

-