Exhaust Emission Control System: Installation

1. Clean the joints.
2. Lift exhaust pipe and hook it onto its rubber mountings. If necessary, change the rubber bushings. See Fig 1 .
3. Install the lower nut between the front exhaust pipe and the turbocharger. Coat the threads with Molykote 1000 or equivalent. See TORQUE SPECIFICATIONS  .
NOTE: To avoid leakage, use NEW clamps when tightening the joints.
NOTE:

Make sure that there is adequate clearance to parts next to the exhaust system. Check that the tailpipe is positioned symmetrically in the space cut out for it in the rear bumper.

4. Bolt the front exhaust pipe and intermediate pipe together, using a NEW clamp.
5. Install the catalytic converter brace and oxygen sensor cables. Lower the car.
NOTE: Tighten the nuts alternately to avoid misalignment of the flange. The exhaust pipe flange must not abut against the turbocharger flange.
6. Install the upper nuts between the front exhaust pipe and the turbocharger. Coat the threads with Molykote 1000 or the equivalent.
NOTE: The oxygen sensor's leads must not be twisted. Make sure that the lead does not rest against hot surfaces or sharp edges.
7. Run the oxygen cables forward and plug in the connector. Secure the cables with a cable tie. See Fig 2 .
8. Install the exhaust manifold's heat shield.
9. Install the bypass pipe with valve. Lubricate the "O" ring at the connection to the turbo inlet pipe with petroleum jelly (Vaseline).
10. Install the top engine cover.

Fig 1: Mounting the Exhaust (B205L/R & B235R)

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Fig 2: Running Exhaust Cables (B205L/R & B235R)

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CAUTION: The oxygen sensor is sensitive to knocks and blows and must be handled with care. It is important to ensure that the connection between it and the nipple is gas tight.
NOTE: Chemicals such as contact spray and grease must not come into contact with the oxygen sensor connectors.
1. Coat the oxygen sensor's threads with Molykote 1000 or equivalent to prevent binding.
2. Install the oxygen sensor. See Fig 1 & TORQUE SPECIFICATIONS  .
3. Run the cable as far up as possible. Lower the car.
   CAUTION: Watch out for sharp edges, hot components, etc.
4. Run the cable forward and plug in the connector. See Fig 2 .
5. Secure the cable to the water pipe with a cable tie.
6. Install the top engine cover.

Fig 1: Installing Oxygen Sensor (B205L/R & B235R)

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Fig 2: Connecting Oxygen Sensor Cable (B205L/R & B235R)

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1. Coat the oxygen sensor threads with Molykote 1000 or equivalent to prevent binding.
2. Install the oxygen sensor. See Fig 1 & TORQUE SPECIFICATIONS  .
3. Lead the cable as far up as it will go. Lower the car.
   CAUTION: Watch out for sharp edges, hot components, etc.
NOTE: Chemicals such as contact spray and grease must not come into contact with the oxygen sensor connectors.
4. Draw out the cable and plug in the connector. See Fig 2 .
5. Fasten the cable to the water pipe with a cable tie.
6. Install the upper engine cover.

Fig 1: Installing Oxygen Sensor (9-5 - B235E/R)

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Fig 2: Connecting Cables to Oxygen Sensor (9-5 - B235E/R)

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CAUTION: The oxygen sensor is sensitive to knocks and blows and must be handled with care. It is important to ensure that the connection between it and the nipple is gas-tight.
NOTE: Chemicals such as contact spray and grease must not come into contact with the oxygen sensor connectors.
1. Coat the oxygen sensor's threads with Molykote 1000 or equivalent to prevent binding.
2. Install the oxygen sensor. See Fig 1 & TORQUE SPECIFICATIONS  .
3. Run the cable forward and plug in the connector. See Fig 2 .
4. Secure the cable to the water pipe with a cable tie.
5. Install the heat shield and bypass pipe.
6. Install the top engine cover.

Fig 1: Installing Front Oxygen Sensor (B205L/R & B235R)

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Fig 2: Connecting Cables to Front Oxygen Sensor (B205L/R & B235R)

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1. Coat the oxygen sensor threads with Molykote 1000 or equivalent to prevent binding.
NOTE: Chemicals such as contact spray and grease must not come into contact with the oxygen sensor connectors.
2. Install the oxygen sensor. See Fig 1 & TORQUE SPECIFICATIONS  .
3. Draw out the cable and plug in the connector. See Fig 2 .
4. Fasten the cable to the water pipe with a cable tie.
5. Install the heat shield and bypass pipe.
6. Install the upper engine cover.

Fig 1: Installing Front Oxygen Sensor (9-5 - B235E/R)

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Fig 2: Installing Cables & Heat Shield (9-5 - B235E/R)

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Coat the oxygen sensor threads sparingly with Molykote 1000 or equivalent.

1. Install the oxygen sensor. See Fig 1 & TORQUE SPECIFICATIONS  .
2. Carefully thread the cable back to the oxygen sensor connector.
3. Install the oxygen sensor connector to the mounting.
4. Install the crankshaft position sensor connector to the mounting.
5. Install the engine cover.

Fig 1: Installing Oxygen Sensor (9-5 - 4-Cyl)

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Coat the oxygen sensor threads sparingly with Molykote 1000 or equivalent.

1. Install the oxygen sensor. See Fig 1 & TORQUE SPECIFICATIONS  .
2. Carefully thread the cable back to the oxygen sensor connector. Secure the oxygen sensor cable with a cable tie.
3. Lower the car to the floor and plug in the oxygen sensor connector. See Fig 2 .

Fig 1: Installing Oxygen Sensor (9-5 - V6)

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Fig 2: Oxygen Sensor Connector (9-5 - V6)

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NOTE: Be careful not to mix up the hoses.
1. Re-install the hoses in their correct positions. See Fig 1 .
2. Hook the evaporative emission canister in place.
3. Make sure the acoustic absorber is installed correctly.
4. Install the fender liner and wheel. See Fig 2 & TORQUE SPECIFICATIONS  .
5. Lower the car to the floor.

Fig 1: Connecting Hoses & EVAP Canister (9-3)

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Fig 2: Installing Fender Liner & Wheel (9-3)

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1. Connect the hoses and install the EVAP canister. See Fig 1 .
2. Install the fender liner. See Fig 2 .
3. Install the wheel. See TORQUE SPECIFICATIONS  .
4. Lower the car to the floor.

Fig 1: Installing EVAP Canister (9-5)

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Fig 2: Installing Wheel Liner (9-5)

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1. Install the hoses. See Fig 1 .
2. Install the valve to the holder.
3. Plug the connector into the EVAP canister purge valve.

Fig 1: Installing EVAP Purge Valve (B235R)

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To install, reverse removal instructions.

1. Connect the purge valve to the connecting hose. See Fig 1 .
2. Plug in the purge valve connector.
3. Install the purge valve to the bracket.
4. Install the quick-release coupling on the purge hose connected to the evaporative emission canister.

Fig 1: Installing EVAP Purge Valve (9-5 - V6)

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1. Install the hoses to the secondary air injection pump. See Fig 1 .
2. Check that the three bushings are correctly positioned and do not fall out, see illustration. Position the pump, attach the connector to the bracket and bolt on the pump with the three bolts.
3. Plug in the connector for the secondary air injection pump.
4. Lower the car to the floor.

Fig 1: Installing Secondary Air Injection (SAI)

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1. Install the SAI valve on the pipe. Use a NEW gasket. See Fig 1 .
2. Connect the hose and check the connection.
3. Install the SAI pipe with NEW gaskets to the exhaust manifold and cylinder head.
4. Fasten the oxygen sensor connectors to the holder. See Fig 2 .

Fig 1: Installing Secondary Air Injection Valve (SAI)

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Fig 2: Connecting Oxygen Sensor Connectors (SAI)

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NOTE: The gasket between the inlet pipe and the valve must always be changed after removing the secondary air injection valve.
1. Install the secondary air injection valve to the inlet pipe with a NEW gasket. See Fig 1 .
2. Install NEW gaskets and connect the inlet pipe to the front exhaust manifold and cylinder head.
3. Connect the air hose to the valve. Check the connection. See Fig 2 .
4. Install the heat shield over the front exhaust manifold.
5. Install the charge air pipe.
6. Raise the car.
7. Install the charge air pipe to the charge air cooler with the clip. See Fig 3 .
8. Lower the car to the floor.
9. Connect the charge air pipe to the throttle body.
10. Plug in the connector for the temperature/pressure sensor on the charge air pipe.
11. Install the bypass pipe with valve using a NEW "O" ring for the connection to the turbocharger inlet pipe.
12. Install the engine cover.

Fig 1: Installing Valve & Inlet Pipe (SAI)

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Fig 2: Connecting Air Hose & Heat Shield (SAI)

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Fig 3: Connecting Charge Air Pipe & Temperature Sensor (SAI)

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1. Insert the SAI pipe and connect it to the rear valve. Check the connection. See Fig 1 .
2. Connect the SAI pipe to the front valve and attach the pipe to its mounting. Check the connection.
3. Connect the hose from the SAI pump to the pipe.
4. Install the turbocharger delivery pipe to the throttle body and charge air cooler.
5. Raise the car and tighten the hose clip on the connection to the charge air cooler. See Fig 2 .
6. Lower the car and tighten the hose clip on the connection to the throttle body.
7. Plug in the connector for the temp/pressure sensor.
8. Install the bypass pipe with valve.
9. Install the engine cover.
10. Move the battery tray sideways away from the engine as far as possible. Install the battery tray, the battery with vent hose and the battery cover.
11. Set the clock and program the radio code where applicable.

Fig 1: Connecting Secondary Air Injection Pipe (SAI)

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Fig 2: Connecting Hose Clamps & Battery Tray (SAI)

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1. Position the filter in the casing. See Fig 1 .
2. Install the air filter casing.
3. Check that the three bushings are correctly positioned and do not fall out, see illustration. Position the pump, and tighten the three bolts.
4. Lower the car to the floor.

Fig 1: Installing Secondary Air Injection (SAI) Filter

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1. Clean the sealing surfaces and Install the SAI valve with a NEW gasket. See Fig 1 .
2. Connect the hose to the valve. Check the connection.
3. Connect the turbocharger delivery pipe to the charge air cooler and throttle body. See Fig 2 .
4. Raise the car, connect the turbocharger delivery pipe to the charge air cooler and throttle body. Tighten the hose clip on the charge air cooler.
5. Lower the car and tighten the hose clip on the throttle body.
6. Plug in the connector for the temp/pressure sensor.
7. Install the bypass pipe with valve.
8. Install the upper engine cover.

Fig 1: Connecting Secondary Air Injection Valve (SAI)

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Fig 2: Connecting Turbo Delivery & Bypass Pipe (SAI)

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