Exhaust System: Service and Repair

Removing and Installing Exhaust System:

KAT (catalytic converter):

RUF (reconversion model):

A Engine 116
B Engine 117

O2 Sensor heating coil connector (G3/2x1) and O2 Sensor signal connector (G3/2x2)
detach in passenger compartment, plug together.

Heat baffle plate (2c)
remove, fit on. Pay attention to installed position.

O2 sensor (G3/2)
unscrew, install.

Installation Instruction:
- Coat thread with paste 000 989 88 51.
- Ensure line is correctly laid.

Screws (4)
unscrew, screw in. Renew screws (4).
Tightening torque 25 Nm.

Final silencer (9)
detach from rubber ring (18) and take off, fit on and attach.

Installation Instruction: Check final silencer (9), rubber ring (18) and rubber stop (13) for signs of wear, replace if necessary.

Rubber rings (18, 25)
detach, attach. Examine for signs of damage and wear.

Exhaust system
take off, install.

Riveted nuts (1)
Remove at exhaust manifold, install. Knock out riveted nuts with suitable tool (e.g.: bolt).

Installation Instruction: Install riveted nuts with caulking bolt 103 589 01 39 00. Tightening torque of caulking bolt 30 Nm.

Exhaust system
check for leaks with engine running.








2 Front exhaust pipe
3 Self-locking nut
5 Sintered seal
5a Flange
5b Graphite seal
7 Center exhaust pipe
8 M8 bolt

NOTE:
- If necessary, clean any combustion or corrosion residues off the tapered connection pieces of the pipes (2, 7) and sintered seal (5) with emery cloth.
- Ensure parts are correctly installed.
- Always renew self-locking nuts and asbestos or graphite gasket after being used once.





To renew the final silencer, place new silencer with socket fitting exactly over removed system and mark pipe length of new silencer at the removed system.
Cut through the pipe at a point 80 minus 10 mm from the marking in the direction of the final silencer in order to obtain an insertion depth of 70-80 mm.





Do not tighten the flanged joint to the exhaust manifold until the complete system is attached in the rubber rings. Ensure that the front exhaust pipe is correctly located. Tightening torque of hex. bolts 20-25 Nm.