Installing Rear Silencer - Turbo

Information 

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

• Torx screws: (E..) for external Torx, (T..) for internal Torx. 
• Hexagon-head bolts (internal and external hexagon): Wrench size (a/f) 

1. Grease the screw thread and clamps with high-temperature grease Optimol Paste MF (Part No. 000.043.207.07) before installation.

   Information 

   • The help of another person is required for removing and installing the silencer. 
2. Pre-fit the catalytic converter (cylinder bank 1-3) on the removed rear silencer. Do not tighten the clamp yet.
3. Fit the rear silencer and catalytic converter for cylinder bank 1-3 on the catalytic converter for cylinder bank 4-6 -arrow 1-  . Do not tighten clamp yet.
   1. 3.1. Get another person to hold the rear silencer. 
      Fig 1: Installing Rear Silencer/Catalytic Converter (Cylinder Bank 1-3)

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4. Fit a new metal seal on the turbocharger and slide the catalytic converter (cylinder bank 1-3) onto the threaded bolts on the turbocharger -arrow 2-  .
   1. 4.1. Position heat shield at the threaded bolts.
   2. 4.2. Fit and tighten four M8 hexagon nuts (a/f 13) on the threaded bolts.

      → Tightening torque: 25 Nm (19 ft. lb.) 

5. Secure the rear silencer.
   1. 5.1. Position two restraining straps on the holder and tighten the two M8 cheese head bolts.

      → Tightening torque: 15 Nm (11 ft. lb.) 

      Fig 2: Positioning Restraining Straps On Holder

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   2. 5.2. Tighten clamps -1-  at the connection points between the rear silencer and catalytic converter.

      Assembly position 45°, screw head facing backwards 

      → Tightening torque: 55 Nm (41 ft. lb.) 

      Fig 3: Identifying Clamping Sleeve Installation Position

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      1. Clamps
      2. Restraining straps
         Fig 4: Identifying Rear Silencer Mounting

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6. Route electric lines for oxygen sensors -1 and 2-  .
   1. 6.1. Guide the oxygen sensor lines at the side of the engine to the plug connections in the engine compartment and clip them into the line brackets -arrows-  .
      Fig 5: Locating Oxygen Sensors

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   2. 6.2. Close the plug connections -1 and 2-  for the oxygen sensors and clip the connectors into the holders.
      Fig 6: Identifying Oxygen Sensor Connectors (Cylinder Bank 1-3)

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