Installing The Three-Way Catalytic Converter (TWC) And Front Exhaust Pipe

Fig 1: Three-Way Catalytic Converters And Front Exhaust Pipe

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Install the catalytic converter and the heat deflector plate.

Use a mobile jack with universal plate 9995972 as a support.

Use the new nuts and gaskets.

Lubricate the studs on the turbocharger (TC). Use copper paste 116 1408  .

Connect to the rear exhaust pipe flange. Install the nuts by hand.

Then connect the exhaust system to the turbocharger (TC). Install the nuts by hand.

Install the brake pipe in the holders on the SIPS member.

Install the screws for the front SIPS member.

Remove the mobile jack.

Tighten the screws for the front SIPS member and the connection to the rear exhaust pipe.

Install the center SIPS member.

Connect the connector for the rear heated oxygen sensors (HO2S) and clamp the wiring.

Fig 2: Lower Oil Cooler Hose & Lower Radiator Hose

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Install: 

• the lower oil cooler hose to the transmission
• the lower radiator hose.

Fig 3: Ball Joint/Control Arm, Tie Rods, Anti-Roll Bar Links, ABS Sensors, Cable For ABS Sensor & Brake Pipe Bracket In Wheel Arch

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Tighten the ball joint/control arm. See: Summary of tightening torques for specific components . Counterhold using Torx 40 so that the ball joint boot does not rotate.

Install 

• the tie rods. Use new locknuts  . Tighten to 70 Nm  .
• the anti-roll bar links. Use new locknuts  . Tighten to 50 Nm  .
• new center screws for the drive shafts  . Tighten to 50 Nm  .
• ABS sensors. Tighten to 10 Nm  .
  NOTE:

  Ensure that the ABS sensor seats are absolutely  clean.

• the cable for the ABS sensor in the mounting in the spring strut
• the brake pipe bracket in the wheel arch.

Fig 4: Engine Splash Guard

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Install 

• the front splash guard
• the splash guard under the engine
• the wheels. See Installing wheels .

Fig 5: Removing/Installing Lowering Steering Shaft

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• the bearing in the lower steering shaft. Secure it in the rubber boot using a tie strap
• the steering shaft joint in the lower steering shaft. Use a new screw and locknuts  . Tighten to 30 Nm  .
  NOTE:

  Previous measurement for correct steering gear position.

• the panel under the dashboard.

Fig 6: Intake And Charge Air Pipes, Turbocharger And Upper Heated Oxygen Sensors

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Tighten the three-way catalytic converters (TWC) to the turbocharger (TC). Use new nuts.

Tighten to 24 Nm  .

Install: 

• the upper heated oxygen sensors (HO2S). Lubricate the threads using copper paste 116 1408  . Tighten to 45 Nm  .
• the heat deflector plates.

Fig 7: Engine And Stabilizer Brace

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Install: 

• the connector for the heated oxygen sensor (HO2S) (turbocharger (TC) 2)
• the intake and charge air pipes
• the plastic charge air pipe
• the plastic intake pipe
• the connector for the heated oxygen sensor (HO2S) (turbocharger (TC) 1). Clamp the wiring for the heated oxygen sensors (HO2S)
• the screw for the mounting for the torque rod on the engine
• the engine stabilizer brace between the suspension turrets.

Fig 8: AC Compressor

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• the air conditioning (A/C) compressor. Tighten to 25 Nm  .
• the connector to the dryer bottle
• the magnetic clutch connector with the engine wiring
• the auxiliaries belt
• the hose between the charge air cooler (CAC) and the turbocharger (TC) pipe. Applies only to B6xx4T  .
• the upper radiator hose.

Fig 9: Engine Control Module

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Connect the engine and transmission wiring connectors to the control module box base plate.

Press the base plate into place in the lower section of the control module box.

Install the intermediate section.

Locate the ventilation pipe in the rear edge of the control module box.

Screw the control module box into place in the fender liner.

Press the control modules down carefully. Lock into place using mounting bracket 9995722 .

Press the cover into place. Screw the ground cable into place.

Fig 10: Expansion Tank And Servo Reservoir

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Install 

• the expansion tank. Connect the hose from the radiator to the expansion tank
• the servo reservoir.

Fig 11: View Of Fan Shroud On Radiator, Connectors To Engine Cooling Fan (FC), Evaporative Emission System (EVAP) Valve And Pulsed Secondary Air Injection System (PAIR) Pump & Wiring To Terminal Block

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• the fan shroud on the radiator
• the connectors to the engine cooling fan (FC), evaporative emission system (EVAP) valve and pulsed secondary air injection system (PAIR) pump
• the wiring to the terminal block.

Secure the wiring.

Fig 12: Charge Air Pipe To Charge Air Cooler (CAC), Upper Oil Cooler Hose To Transmission & Transmission Cable To Transmission

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• the charge air pipe to the charge air cooler (CAC). Applies only to B6xx4T  .
• the upper oil cooler hose to the transmission
• the transmission cable to the transmission.

• the air intake pipe to the air cleaner (ACL) housing in the fan shroud
• the brake servo hose to the intake manifold
• the air cleaner (ACL) housing with all connections.

Fig 13: Air Cleaner Housing Assembly

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• the positive cable to the positive terminal block
• the negative battery cable. First read Battery, disconnecting .