Work Procedure
1. Preparation.Cabriolet only:
Take hardtop off the vehicle (Technical Manual, Group 6, Serv. No.6102), move convertible top to service position (61 02 79, Page 61-69 Removing the hardtop), and disengage both tension cables.
Remove battery cover. Disconnect and cover the battery.
1.1 Position vehicle on lifting platform, taking care not to damage any side member panels from the Exclusive/equipment product range.
1.2 Rear of vehicle:
1.21 Remove rear spoiler (Technical Manual, Group 6, 63 55 19, Page 63-7).
1.22 Remove both exhaust tailpipes and V-band clamps.
1.23 Remove both side heat shields and main mufflers.
1.3 Engine:
1.31 Remove air cleaner housing.
1.32 Remove throttle with intermediate part and both rubber sleeves (Technical Manual, Group 2, 24 46 37, Page 24-5). Cover or seal all line openings with a cleaning cloth or similar.
1.33 For the installation of an additional vacuum connection, check whether a connection nipple is already present on the left rubber sleeve of the tuning pipe on the intake distributor; to do so, remove the throttle, md. the rubber sleeves.
No: Remove rubber sleeve and replace with the rubber sleeve with connection nipple (scope of parts).
If the hose clamps interfere with installation, support the engine with a car jack and unscrew both the hexagon nuts on the rear engine mounts as far as the next-to-the-last turn (Technical Manual, Group 1, 10 01 19, Page 10-1).
Yes: Check the remaining rubber sleeves (3 pieces, 2 already removed) for an available connection nipple. Replace one rubber sleeve without connection nipple with the rubber sleeve with connection nipple (scope of parts).
1.4 Vehicle interior:
1.41 Remove radio or PCM (Technical Manual, Group 9, 91 10 19, 91-7 Page 1).
Note:
If there is no longer a slot free in the upper section of the center console (switch cover) for the sports exhaust system switch, installed it in the center console area.
In this case: remove center console (Technical Manual, Group 6, 68 17 19, Page 68-9).
1.42 Remove driver-side front seat (Technical Manual, Group 7, 72 01 19, 72-1 Page 1).
1.43 Remove fuse and relay carrier 1, carpet lining and the center console trim panel on the drivers side.
1.44 Uncover the driver-side door sill by detaching the sill cover (Technical Manual, Group 5, 55 10 37, 55-29 Page 1) and removing the carpet.
1.45 Remove driver-side side-panel lining (Technical Manual, Group 7, 70 75 19, 70-39, Page 1).
1.46 Only for vehicles with Bose sound system, M-Option 680, remove passenger-side side panel lining and bass box from the rear luggage rack.
1.47 Remove the rear seat backs and the rear seat panel
1.48 Coupe only:
Left-hand drive: Remove passenger-side side-panel lining
(Technical Manual, Group 7, 70 75 19, 70-39, Page 1).
All: Remove the trim under the rear window and the moulded foam on the right C-pillar. Remove clips from the trim and reclip to the member (under the rear window).
Cabriolet only:
Remove the moulded carpet under the convertible-top compartment lid.
2. Install and connect the two electrical wiring harnesses.
2.1 Lay wiring harness for the switch.
Note:
The switch should preferably be installed in the bottom right position in the switch cover (see Figure 2) or just to the left of the radio/PCM.
Alternatively, if there is no space left in the switch cover, the switch may also be installed in the lower section of the center console (area of the handbrake lever).
2.1.1 If necessary, wrap adhesive tape around the wiring harness before laying.
2.1.2 Run the five leads (1 x RE/GR; 2 x GR/BU/BN, 1 x GR/GN and 1 x RE/BU) with the three flat connectors from the chosen installation location of the switch to the holder of the lower section of the center console.
2.1.3 Detach the adhesive tape fixing the left and right footwell trim to the center tunnel and lay the leads under the steering column and over the pedals to the relay or fuse carrier, ensuring there is no chafing or tension.
2.1.4 Fasten wiring harness to existing wiring/components with adhesive tape or a tie-wrap.
2.1.5 Mount switch socket into the chosen slot.
2.1.6 Fit switch cover and switch.
2.2 Install relay socket for the second wiring harness.
2.2.1 Run the three leads (1 x GR/RE; 1 x BR and 1x GR/PK) of the relay socket through any free slot in relay carrier 1, noting the direction of installation of the relay socket.
2.2.2 Release the relay socket at the sides and assign the openings in the relay socket according to the table.
2.2.3 Lock the relay socket and insert in the chosen slot in relay carrier 1.
2.3 Wrap both wires, approx. 7000 mm long (1 x GR/RE; 0.52 from relay and 1 x RE/BU; 0.52 from switch) together with adhesive tape.
2.4 Connect the wires from the switch socket according to the table.
2.5 Lay wrapped wires (GR/RE; 0.52 from relay and 1 x RE/BU; 0.52) along side member to B-pillar.
2.6 Lay wrapped wires to the rear of the vehicle.
2.6.1 Cabriolet: Lay the wiring from the B-pillar along the Bowden cable for the rear lid as far as the convertible-top compartment lid. Lay the wiring harness underneath the convertible-top compartment lid aloneside existing wiring to the grommet (Figure 3, Item A) located on the right in the firewall of the rear end.
2.6.2 Coupe:
Detach panel in the engine compartment beneath grommet (Figure 3, Item B).
Left-hand drive:
Lay wiring harness from the B-pillar along the cover panels for the control modules to the grommet (Item B).
Caution!
Risk of damage to components in the engine compartment during drilling due to drill chuck or drill.
> Remove existing components from the drilling area (engine compartment).
> Mask drilling area and use a power drill with bit stop.
2.7 Cabriolet:
Drill or pierce a hole 4.5 mm in the collar of the grommet (Figure 3, Item A) at the desired breaking point in the 11 o'clock position.
Coupe:
Drill or pierce a hole 4.5 mm in the plug 19.6 mm (Figure 3, Item B).
2.8 Feed the wiring harness through the bore into the engine compartment and fasten to the existing wiring/components with adhesive tape or a tie-wrap.
3. Functional diagram (Figure 4) of pneumatic control of the exhaust flaps.
Vacuum direction:
- From the rubber sleeve on the tuning pipe via the check valve (Figure 4, Item A), if necessary via the vacuum tank (Item B);
- via the switch-over valve, with the support (Item C) clipped on the underside, and the Y-piece to the vacuum modulator on the mufflers.
4. Install new exhaust system.
4.1 Loosely pre-fit both exhaust tailpipes and install the two new main mufflers.
Note:
For vehicles from MY 99 (X) up to and including MY 01(1) the new mufflers can only be fitted using the existing muffler holder on the engine.
4.2 Installing pneumatic control components
4.2.1 Install the rubber sleeve with connection nipple on the left side of the tuning pipe or where the rubber sleeve without connection nipple was removed (see Item 1.3.3). The connection nipple should point towards the rear on the underside (Figure 5).
4.2.2 Insert hose (Tekalan) at least 25 mm deep into the connection nipple (Figure 5, Arrow) and lay to the plastic housing of the positive terminal in the engine compartment.
4.2.3 Remove cleaning cloth and install throttle including rubber sleeves.
4.2.4 Push Y-piece (Figure 6, Item B) onto the connection nipple on the vacuum tank (Item A) as far as the stop.
4.2.5 Insert white side of the check valve (Item C) as far as it will go into an output of the Y-piece (Item B). Push the bent protective sheath (Item D) onto the black side of the check valve as far as it will go.
4.2.6 Remove the rearmost fastening screw of the fuel collection pipe (Item E). Install the fuel collection pipe and the vacuum tank with spacer sleeve and new hexagon-head bolt M6 x 80 in the same position (Figure 6).
4.2.7 Lay the hose (Tekalan) from the rubber sleeve on the tuning pipe (Figure 5, Arrow) to the protective sheath (Figure 6, Item D), cut to the correct length and insert the hose 10 mm deep into the protective sheath.
4.2.8 Insert switch-over valve (Figure 7, item A) into the holder supplied (Item B). Insert the bent protective sheath (Item C) and Y-piece (Item D) into the connections on the switch-over valve as shown in Figure 7.
4.2.9 Mount switch-over valve above the positive terminal in the engine compartment.
4.2.10 Insert the hose (Tekalan) 10 mm deep into the free connection of the Y-piece of the vacuum container (Figure 6, Item B) and lay to the bent protective sheath (Figure 7, Item C).
4.2.11 Trim the hose (Tekalan) and insert 10 mm deep into the bent protective sheath (Item C).
4.3 Connect the switch-over valve electrically.
4.3.1 Guide a single blue seal (scope of delivery) onto each electrical wire to the switch-over valve and crimp jacks onto both wires.
4.3.2 Release socket housing and insert wires according to the table.
4.3.3 Lock socket housing and make plug connection to switch-over valve (Figure 7).
5. Connect vacuum modulators of both mufflers.
5.1 Left side.
5.1.1 Lay the remaining hose (Tekalan) from the connection of the switch-over valve pointing to the left to the bore in the left wheel housing (corner of the rear closing panel/left side wall).
5.1.2 Make a hole approx. 4 mm in the rubber sleeve 25 x 22 mm (scope of delivery) and push the rubber sleeve onto the hose, observing the direction of installation.
5.1.3 Route hose (Tekalan) through the bore in the wheel housing to the steel-armoured hose of the vacuum modulator and trim.
5.1.4 Push the hose at least 10 mm into the steel-armoured hose and fasten with a hose clamp (8 mm).
Note:
Due to the high temperatures, the steel-armoured hose must cover at least the area under the heat shield as far as the vacuum modulator on the muffler (Figure 8).
5.2 Right side.
5.2.1 Insert the remaining hose (Tekalan) 10 mm deep into the right connection of the Y-piece on the switch-over valve and, for the right vacuum modulator, work through steps similar to those in 5.1.1 to 5.1.4.
6. Concluding work.
6.1 Fit fuse carrier and relay carrier 1, and insert the relay into the relay socket of the electrical wiring harness.
6.2 Install trims, rear seat assembly and front seat.
6.3 Tighten both rear engine mounts (Technical Manual, Group 1, 10 01 19, Page 10-1). Tightening torque: 85 Nm (63 ftlb.).
Install components in the engine compartment (air cleaner housing, oil filler neck, etc.).
6.4 Lower the vehicle until the wheels touch the ground.
6.5 Connect battery and PST2
Cabriolet only:
Close convertible top and calibrate if necessary
(Technical Manual, Group 6, 61 01 19, 61-1 Page 13, Test Step # 11).
6.6 Carry out function test on the sports exhaust system.
6.6.1 Switch ignition on and select the vehicle type in the PST2.
6.6.2 Select menu item Instrument cluster and then menu item Speedometer A-signal.
6.6.3 Start the engine and increase the speedometer A-signal in steps of 10 up to 70 kmh /45 mph by pressing the F5 key.
6.6.4 Have a second person visually check the operation of the exhaust flaps. The flap function is indicated by the movement of the linkage from the vacuum modulator to the exhaust flap. If the flaps function as intended, vacuum is present at the vacuum modulators at a speed of approx. 45 kmh / 28 mph to approx. 68 kmh / 42 mph. The exhaust flaps are closed in this case (closing process: linkage moves up).
6.6.5 Use the F6 key to reset the speedometer A-signal in the digital display of the instrument cluster to 0 kmh/ 0 mph.
6.6.6 Switch off the engine sound of the sports exhaust system in the loud speed ranges by pressing the tailpipe symbol on the switch (center console). If operation is correct, the light-emitting diode in the switch starts to light up.
6.6.7 Press the tailpipe symbol once more to switch on the engine sound of the sports exhaust system again. The light-emitting diode must go out in this case.
Note:
Switching operations with the switch must only be triggered by pressing the tailpipe symbol. If only one switching operation is triggered by pressing the light-emitting diode, check the assignment of the openings in the switch socket and change if necessary.
6.7 Install both side heat shields and bumper mount with rear spoiler (Technical Manual, Group 6, 63 55 19, Page 63-7).
6.8 Align the exhaust tailpipes in the cut-outs of the rear spoiler and screw the V-band clamps tight.
6.9 Input radio code and set the time in the instrument cluster.
6.10 Remove the vehicle from the lifting platform, perform a test drive and then read out control units with the PST2. Erase fault memory if necessary.
7. Fault symptoms, possible faults and remedy.
7.1 Exhaust system flaps perform only one control operation: Connection on switch-over valve interchanged (Fig. 4, Item C).
Connect vacuum hoses as shown in the diagram in Figure 5.
7.2 CHECK ENGINE emission control warning light flashes or is continuously lit Intake system leaks:
Read out fault memory of DME control unit with the PST2 and, if necessary, carry out a short test. Leak-test the components and the Intake air distributor with the pressure tester (special tool 9264/6 - see Workshop Equipment Manual, Chapter 2.2b), and check the insertion depth of the hoses (Tekalan).
7.3 Exhaust flaps do not react fully or do not react under fast acceleration: The reason for this is the slower response of the mechanics (exhaust flaps) in relation to the pneumatics (vacuum).