Remove/install catalytic converter or front exhaust system

AR49.10-P-5531L

18.1.10

ENGINE 137.970 in MODEL 215.378

ENGINE 137.970 in MODEL 220.178 /878

Remove/install catalytic converter or front exhaust system

P49.10-2140-09

11/1 Bolts

11/2 Bolts

11/3 Bolts

11/4 Bolts

11/5 Nuts

11/6 Sealing rings

157/3 Firewall catalytic converter for

Cylinders 7-9

157/4 Firewall catalytic converter for

cylinders 10-12

158 Three-way catalytic converters

G3/7 Left O2 sensor upstream TWC [KAT]

for cylinders 7-9

12 Shield

13 Shield

13/1 Bolts

157/1 Firewall catalytic converter for

cylinders 1-3

157/2 Firewall catalytic converter for

cylinders 4-6

 	Remove, Install
1	Remove lower engine compartment lining		AR61.20-P-1105M
2	Separate plug connections of O2 sensors		AR14.00-P-5303L
	Left side of engine
3	Unscrew bolts (11/1) of firewall catalytic converter (157/4) at exhaust manifold	If bolts are stiff, or thread damaged:
		Replace the rivet nuts in the exhaust manifold.	AR49.10-P-5531-01DA
		Bolts	*BA14.10-P-1002-01B
4	Unscrew bolts (11/2) of flange connection of firewall catalytic converter (157/3) at firewall catalytic converter (157/4)		*BA49.10-P-1002-01G
5	Unscrew bolts (11/3) of flange connection of left front exhaust system at right front exhaust system		*BA49.10-P-1002-01G
6	Unscrew bolts (11/4) at flange connection of front exhaust system/rear exhaust system		*BA49.10-P-1002-01G
7	Unscrew nuts (11/5) from bracket on left	 Replace nuts.
8	Take out front exhaust system together with firewall catalytic converter (157/4)
9	Unbolt shield (12) of firewall catalytic converter (157/3)
10	Unscrew bolts (13/1) and take off shield (13)
11	Remove oxygen sensor left, upstream of TWC (G3/7)		AR14.00-P-5303L
12	Unscrew bolts (11/1) of firewall catalytic converter (157/3) at exhaust manifold	If bolts are stiff, or thread damaged:
		Replace the rivet nuts in the exhaust manifold.	AR49.10-P-5531-01DA
		Bolts	*BA14.10-P-1002-01B
13	Take out front exhaust system together with firewall catalytic converter (157/3)
	Right side of engine
14	Unscrew bolts (11/1) of firewall catalytic converter (157/2) at exhaust manifold	If bolts are stiff, or thread damaged:
		Replace the rivet nuts in the exhaust manifold.	AR49.10-P-5531-01DA
		Bolts	*BA14.10-P-1002-01B
15	Unscrew bolts (11/2) of flange connection of firewall catalytic converter (157/1) at firewall catalytic converter (157/2)		*BA49.10-P-1002-01G
16	Unscrew nuts (11/5) from bracket on right	 Replace nuts.
17	Take out front exhaust system together with firewall catalytic converter (157/2)
18	Unscrew bolts (11/1) of firewall catalytic converter (157/1) at exhaust manifold	If bolts are stiff, or thread damaged:
		Replace the rivet nuts in the exhaust manifold.	AR49.10-P-5531-01DA
		Bolts	*BA14.10-P-1002-01B
19	Take out front exhaust system together with firewall catalytic converter (157/1)
20	Install in the reverse order	Installation: Install catalytic converters (158) free of stress.
		 Inspect sealing rings (11/6) for re-usability, install new ones if necessary.
	Notes regarding disposal of three-way catalytic converters		OS49.10-P-1000-01A

 Exhaust manifold

Number	Designation		Engine 137


BA14.10-P-1001-01B	Nut on exhaust manifold	NM	16
BA14.10-P-1002-01B	Exhaust manifold flange connection and front exhaust pipes	NM	20

 Exhaust system

Number	Designation		Engine 137


BA49.10-P-1002-01G	Flange connection to exhaust pipes	NM	20

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