Front Exhaust Pipe w/Catalytic Converter Removal (B205L/R & B235R)
When changing the front exhaust pipe, the oxygen sensors must be removed and installed to the new exhaust pipe. Apply Molykote 1000 or equivalent to the threads on the oxygen sensors before installing.
CAUTION:
The leads of the oxygen sensors must not be twisted. Twisted leads are susceptible to vibration and the leads could break. Since the oxygen sensors are sensitive to impact and shock, they must be handled with care.
- Remove the bypass pipe with valve. Keep the "O" ring where the pipe is connected to the turbo inlet pipe. See Fig 1 .
- Remove the exhaust manifold heat shield and the top engine cover.
- Unplug the oxygen sensor connectors. Cut the cable tie securing the oxygen sensor cables and adjust their position so that they run free when the pipe is removed.
- Remove the 2 upper nuts on the joint between the turbocharger and the front exhaust pipe. See Fig 2 .
- Raise the car.
- Remove the lower nut on the joint between the turbocharger and the front exhaust pipe as well as the bolt on the catalytic converter brace.
- Remove the clamp at the joint between the front exhaust pipe and the intermediate pipe.
- Unhook the exhaust pipe from its rubber mountings and lower it away. Make sure that the leads of the oxygen sensors are not caught up or damaged when the exhaust pipe is removed.
NOTE:
The flexible section in the front part of the exhaust pipe must not be bent more than 5 degrees.