7000 - Removal and installation of the exhaust system Engine 103 in A. Model 107, B. Models 124, 126, 201, C. Model 129

Preceding work:

Removing and installing engine compartment panel
Removing and installing, replacing and bolting exhaust system as of plug connection (49-7280).

Operation no. of operation texts and work units or standard texts and flat rates:

49-7000.

Plug connection, oxygen sensor heating coil

(G3/2x1) and plug connection, oxygen sensor

signal (G3/2x2)

in right footwell, below cover plate, separate, plug together.

Heat shield (2c)

pull off, fit on. Pay attention to installation position.

Oxygen sensor (G3/2)

unscrew, install.

Installation note

Coat thread with paste 000 989 88 51.
Ensure the cable is correctly routed.

Bolts (27)

unscrew, screw in. Take off flame shield (28), fit on (only ).

Bolts (4)

unscrew, screw in. Replace bolts (4).

Tightening torque 25 Nm (reference value).

Rubber rings (18, 29)

detach, attach.

Check whether damaged and worn.

Front exhaust pipe with front and underflow

catalytic converter (2a) or front exhaust pipe

with front and centre silencer (2g)

take off, fit on.

Riveted nuts (1)

at exhaust manifold, remove, install. 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).

Carrier (10)

check suitability for reuse, replace if necessary.

Exhaust system

with engine running, check for leaks.

Plug connection, oxygen sensor heating coil

(G3/2x1) and plug connection, oxygen sensor

signal (G3/2x2)

in footwell, separate, plug together.

Heat shield (2c)

pull off, fit on. Pay attention to installation position.

Oxygen sensor (G3/2)

unscrew, install.

Installation note

Coat thread with paste 000 989 88 51.

Ensure cable is correctly routed.

Retaining bar (31) with dished springs (32) and

self-locking nuts (33)

take off, fit on.Tightening torque 7 Nm (reference value).

Installation note
Check parts and replace if necessary.


Pay attention to illustration note for installing dished springs.

Bolts (4)

unscrew, screw in. Replace bolts (4).

Tightening torque 25 Nm (reference value).

Carrier (30) with bolts (11), washers (12), rubber washers (14) and nuts (23)

take off, fit on. Tightening torque 20 Nm (reference value).

Installation note

Check parts and replace if necessary.

Front exhaust pipe with front and underflow

catalytic converter (2a) or front exhaust pipe

with silencer (2)

take off, fit on.

Riveted nuts (1)

at exhaust manifold, remove, install. Knock out riveted nuts with 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).

Exhaust system

with engine running, check for leaks.

Plug connection, heated oxygen sensor

(G3/2x1)

separate at outside right of transmission tunnel, plug together.

Note

Slackening union nut=counter-clockwise

Tightening union nut=clockwise

Heat baffle (2c)

pull off, fit on. Pay attention to installation position.

Oxygen sensor (G3/2)

unscrew, install.

Installation note

Coat thread with paste 000 989 88 51.
Ensure the cable is correctly routed.

Self-locking nuts (6a)

unscrew, screw on, replace.
Tightening torque 20 Nm (reference value).

Carrier (30) with bolts (11), washers (12), rubber washers (14) and nuts (23)

take off, fit on. Tightening torque 20 Nm (reference value).

Installation note
Check parts and replace if necessary.

Threaded plate (6)

check suitability for reuse, replace if necessary.

Bolts (4)

unscrew, screw in. Replace bolts (4).

Tightening torque 23 Nm (reference value).

Rubber ring (17)

detach, attach. Check for damage and wear.

Front exhaust pipe with underflow catalytic

converter (2d), or front exhaust pipe with

front silencer (2b)

take off, fit on.

Bolt (16)

replace. Tightening torque 25 Nm (reference value).

Holder (15)

check suitability for reuse.

Riveted nuts (1)

at exhaust manifold, remove, install. Knock out riveted nuts with 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).

Exhaust system

with engine running, check for leaks.