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Instrument cluster trim 51 45 030 removing and installing instrument panel trim disconnect battery negative lead. Remove fixture for steering column switch. Remove center console. Remove trim for center console. Remove right glovebox. Remove all clip-fitted trims (on instrument panel). Remove carrier in center console. Remove both panels for front roof pillar. Remove light switch unit. Remove complete instrument carrier. Remove heating controls. If necessary, remove radio receiver. Remove airbag module on passenger side. If necessary, release screw (1).

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Remove lock cylinder completely from front door. Passenger side: remove cover on outside handle. Removal: slacken nut (1) on outside handle (2) (do not release fully). Installation: contact surface (3) of outside handle (2) must rest without play against lock actuator (4). 5az outside handle to lock actuator note: fit the older outer frame (1) of screw cover (damage to paint). Pull outside handle (2) as far outwards/upwards as possible and secure in this position with a screwdriver (3). Note: for removal, the outside handle (1) must remain secured with a screwdriver (3). A pull off outside handle (1) from rear lock actuator b pull off outside handle (1) in lowest setting (as shown in illustration) from front lock actuator (4). Installation: old outer frame (1) of screw cover must be fitted (damage to paint). Press lock actuator (1) with a screwdriver (2) fully into “open” setting. Mount outside handle in this position. Installation: supports (1) and (2) on outside handle (3) must not be damaged. Installation: if necessary, replace faulty seals (1) and (2) for outside handle. Installation: carry out function check only with door open.

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Cause the bowden cables connecting the outer door handles to the latch assemblies may get water inside the outer sheath of the cable. If the temperature drops below freezing before the water dries out, the water may freeze, preventing the movement of the inner cable. Correction as of 7/02 production, the sealing of the outer cable from water penetration was improved by modifying the rubber nipple on the handle end of the cable. In case of a customer complaint, replace the outer door handles with the improved parts. Parts information procedure replace the front door handle assemblies per repair instructions, section 51 21 200. Replace the rear door handle assemblies per repair instructions, section 51 22 200.

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Exhaust system note: removal of exhaust system must be carried out with assistance of a second person. Removal support exhaust system with jack and special tool (31 2 220) and secure against falling out. See fig. 1 . Remove nuts (1) and remove connecting plate (2). See fig. 2 . Remove screw (1) and remove exhaust bracket. See fig. 3 . On sedan and coupe, remove screws (1) and remove reinforcement plate (2). See fig. 4 . Remove screws (3). Reinforcement plate (4) is connected to exhaust system via rubber mounts and does not have to be removed. 5. On convertible, remove screws and remove body reinforcement strut (1). See fig. 5 . Remove screws. See fig. 6 . Reinforcement plate (1) is connected to exhaust system via rubber mounts and does not have to be removed. 6. On all vehicles, if fitted, detach vacuum hose (1) from vacuum unit (2). See fig. 7 . 7. Remove nuts on rubber mount of rear muffler on left and right. See fig. 8 . Lower exhaust system with lifter and remove. 1. 2. 3. 4. Installation 1. 2. 3. 4. To install, reverse removal procedure. Check seals (1). See fig. 9 . Replace, if necessary. Replace self-locking nuts (1). See fig. 2 . Coat threads with copper paste. Slacken screws (2). See fig. 3 . Align exhaust carrier so that it is free from tension.

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1 2 front engine cover intake air duct 3 4 hose air filter housing danger! 1 2 3 4 5 6 7 removing/installing risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/ rear-end door or sliding roof. Open engine hood and raise to vertical position model 209 pull off the front engine cover (1) towards the top. Remove left and right suction fan duct (2) remove air pump hose (3) at air filter installation: the arrows on the hose (3) housing (4) and the air filter housing (4) must point towards each other. Lever off clamp (5) from the air filter housing (4) detach the air filter housing (4) upwards from in order to avoid scratches and damage, the mounts (4) at the left and right cylinder the air filter housing (4) must be put down on head cover a padded base. Installation: apply liquid lubricant to the mounts (4a) on the left and right cylinder head cover. Lubricant *br00.45-z-1002-06a install in reverse order when moving components, ensure that no body parts or limbs are within the operating range of moving parts. Model 203