Exhaust System: Service and Repair
Removing and Installing Exhaust System:
Up to 08/87 KAT Basic Version, National Version Eff. 1986 (USA):
Up to 09/87 RUF:
Effective 09/87 KAT:
Effective 09/87 RUF:
A Engine 117
B Engine 116
O2 sensor heating coil connector (G3/2x1) and O2 sensor signal connector (G3/2x2)
separate in passenger compartment, plug together.
Heat baffle plate (2c)
pull off, 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.
Retaining bracket (6) with Belleville spring washers (17) and self-locking nuts (16)
remove, install. Tightening torque 7 Nm.
Installation Instruction: Check parts and renew if necessary.
Bolts (4)
unscrew, screw in. Renew bolts (4). Tightening torque 25 Nm.
Final silencer (9)
detach from rubber rings (18) and take off; fit on and attach.
Installation Instruction: Check final silencer (9) and rubber ring (18) for signs of wear, replace if necessary.
Center silencer (7)
detach from rubber ring (18) and take off; fit on and attach.
Installation Instruction: Check center silencer (7) and rubber ring (18) for signs of wear, replace if necessary.
Side support (10) with bolts (11), washers (12), rubber washers (14) and nuts (23)
remove, fit on. Tightening torque 20 Nm.
Installation Instruction: Check parts and renew if necessary.
Exhaust system
take off, install.
Rivet nuts (1)
remove at exhaust manifold, install.
Knock out rivet nuts with suitable tool (e.g.: bolt).
Installation Instruction: Install rivet nuts with caulking bolt 103 589 01 39 00 Tightening torque of caulking bolt 30 Nm.
Rubber stop (13)
check for signs of wear, replace if necessary.
Exhaust system
check for leaks with engine running.
Special Tools:
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 off any combustion or corrosion residues on 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 using once.
Before inserting the rear exhaust pipe, first of all support the front exhaust pipes with the clamping bracket and side support, but do not yet tighten at this stage.
Install four Belleville spring washers on each side of the retaining bracket so that the curved faces point away from each other.
To renew the final silencer, place final silencer with socket joint exactly over removed system and mark pipe length of new silencer at the removed system.
Cut through the pipe 80 minus 10 mm from the marking in the direction of final silencer to obtain an insertion depth of 70-80 mm.
Do not tighten the flange 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 bolts 20-25 Nm.