Removing and Installing Front Exhaust System

Front Exhaust System


Replacement
1. Replace self-locking nuts and gaskets. Ensure gaskets and flanges are correctly installed
- Use emery cloth to clean off combustion and corrosion residues at connection points, if necessary.





2. Disconnect connectors (arrows) for oxygen sensor.
3. Replace rivet nuts in exhaust manifold, if necessary.





a. Use a suitable bolt (arrow) to knock rivet nuts out of the holes in the exhaust manifold.

NOTE: Screw bolt in by hand only.





b. Insert new rivet nut into hole of the exhaust manifold.

Caulking Bolt:

c. Screw in caulking bolt and tighten to about 30 Nm.
4. Remove threaded plate.

NOTE:
- Installation of the threaded plate differs according to the transmission version.
- Pay attention to installation of threaded plate

Shown On Model 124 With Engine 111, Others Similar:

- Oblong hole A B C
- Automatic transmission A B
- Manual transmission B C
5. Install in reverse sequence, noting the following:
- Pay attention to TWC thermocouple





- Front exhaust pipes insulated
- The resonance bodies of the front exhaul pipes have been discontinued since 01/1994.
A: Previous version
B: Current version





- The shape and cross section of three way catalytic converter has been modified (standardized catalytic converter). Identical outer dimensions with different lengths of monolith as a function of engine version fitted.
A: Previous version
B: Current version
- On models with catalytic converter code 620a, regarding disposing of catalytic converters:
- Catalytic converters should never be disposed of as scrap. Catalytic converters contain valuable precious metal which can be recycled.
- Since January 1989 we have offered a program for returning catalytic converters and receiving credit for the return value.
- The catalytic converters have been included in the exchange price list (valid as of 2 January 1989) and provided with the footnote "Order new part, reconditioned parts cannot be supplied".
- Details on addresses for return shipment and exchange prices can be obtained from "information on parts and accessories".