Removing and Installing Front Exhaust System

1. Take off bottom engine compartment panel and fit on.
2. Remove exhaust system downstream of flanged connection, install.





3. Unplug oxygen sensor connectors (G3/3x1, G3/4x1).
4. Unscrew bolts (1) at flanged connection of catalytic converter/exhaust manifold.

NOTE: If bolts do not turn easily or if thread is damaged, replace rivet nuts in exhaust manifold.

5. Detach flanged connections at cross pipe (4).
6. Unscrew nuts (6a) at the carrier (10) and take off catalytic converter (2).
7. Unscrew bolts (1) at flanged connection of cross pipe/exhaust manifold.
8. Unscrew oxygen sensor (G3/3, G3/4).
9. Check whether flanges, sintered seal (5) can be re-used. Replace if necessary.
10. Install in reverse order.

Tightening Torques:
Oxygen sensor to exhaust pipe/exhaust manifold - 55 Nm
Flanged connection to cross pipe/exhaust system - 25 Nm
Flanged connection of exhaust manifold or front pipes - 20 Nm

Repair Product
Hot lubricating paste, order number - 000 989 76 51.

Box Wrench Socket. Delco R4 And A6:

Caulking Bolt: