I

49-0001 Conversion of KATversion vehicles to version without KAT(model 140)

Vehicles with catalytic converter (KAT. code620) can be converted to the version withoutKAT.

Disconnect battery.

2 Remove catalytic converter (see 49-5531.section A).

3 Install exhaust system without catalyticconverter (see 49-5531. section 8).Install shIeld for left exhaust pIpe on theunderSide of the car.

4 CIJt off cable at the connector of the lambdasensor (G3.2x 11.

Note

Connector remainS plugged in as insulation.

5 Unplug all the contro units from the modulebox using special tool 140 589 01 33 00.Remove module box.

6 Make up wiring harness as described Instep 18.

RA 49 1321 -0001 1

FI . i i. ~-- .: I

~;~~1' <::'- /.~ -<--

0

P07.2613.13

1'13/1N4t1

Hot Wire (LH) control unit

Eloctronlc aCCClerator pedal CEFP)/Tempomal crUIse conlrol (TPM)Base mOdule

ABS.ASR control Ul1lt

1'116'1N3(j11

7 Aun yellow green cable of the shop-madewiring harness through the side rubber grommetinto the module box. Crimp small flat connector(00354551 26) onto the cable and press Intothe light green lH control untt coupling (withoutCAN) in slot 7.Cut off cable for air pump actuation from light

green coupling. slot 19. and cable fortransmission shift point retard from slot 20 about30 mm behind the flat connector with pliers andinsulate at both ends.

Crimp small flat connector (003 545 51 26) ontothe cable and press into light blue lH controlunat coupling. slot 7 (without CAN).Seal rubber grommet with silicone!

8 Install module bOlc.

Exchange lH control unit (N3 1) and re-Install allthe control units.

&.If the part numbers listed In the table areinstalled (as of 1992). the control unIts shouldnot be exchanged.

9 Unplug lH resistance trimming plug (A17 2).Open coupling. Solder brown 'white cable of theCO potentiometer (R33. step 10) to the brownwhite cable in the coupling of the lH resistancetrimming plug (R17 2).Rt on new resistance trimming pt'ug.

RA 49 1321-0001 2

- ---

ATr'~Inf.r.r

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t

"III6iP RA 49.1321-0001 :1

10 Install CO potentiometer (R33) behind the

right headlamp umt. Plug connector of the shop-made winng harness to (R331.

11 Exchango EZL ignition control UI1.t (N1 3) ifthe control unit Ins~alled does not have thefollowing part no.:In model 140.042043

pa~t no. 012 545 83 32 or 013 545 63 32In model 140.050051

part no. 012 545 85 32 or 013 545 64 32

12 Exchange EZL resistance trimming coupling(R16.2).

Nt 3 EZL AKR '90.1.00 ccnlr::>1,,"'1

Rt62 EZL reSISlance Ir""'">11119CO'JI)hng

13 Exchange igmtion coils (n 1, T1 2) If thecoils installed do not have the following part no.:part no. 000 1565703 or 000 1585503

14 Stick new engine data information plate overthe existing engine data information plate (seelist of parts).

15 Connect battery.

16 Code radio.

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~ jJ/h 11/a~. ''.~

@:l/ '~~""-R33 ~

,/ (~~~---~ q

P07.260i.t3A

P15.2355.13

P 15.2365.13

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-----17 Aunengine to warm up to an olr temperatureof 60 - 80°C and set idle emIsSIonslevel (see

DIagnosisManualEngine. Volume 1. Section"B").

~~

700 --- - /~ . I~~ I 1

I

1050 -' ---- --

!J0.75 b,/wsO.75ge/gn snL

P14.5061-53

18 Shop-made wiring harnessContacts 2 and 3 In the coupling of the COpotentiometer must be bridged.

Note

When performing the conversion work. payattention to the relevant national regulationsregarding vehicle registration.

AA49.132100UOO14

LIst of parts (LHD version)

NoteOperation text and flat ratesConvertingKATvehiclesto vehicleswithout KAT:02-4914-02 Basic operation

Special tool

RA 49.1321-0001,5

Designation Part no. aty. of parts aty. of partsM 119.970 M 119.971

CO potentiometer 00054251 25 1 1Bracket 1405400373 1 1M5x 12'Q.olt . 000933 005059 1 1M6 x 10 bolt 007985 006149 1 1LH resistance trimmIng plug 014545 7028 1 1EZL resistance trimming plug 95 octane 015 545 71 28 1 1EZL resistance trimming plug 91 octane 015545 7028 1 1LH control Unit 01254561 32 - 1lH control unit 012545 62 32 1 -Shield 140 682 21 71 1 1Shield 140682 13 71 1 1Self.tapping screw 007976004215 5 5Front right exhaust pipe 14049001 19 1 1Front left exhaust pipe 140490 14 19 1 1Front exhaust pipe 14049000 is 1 1Bolt 12999004 10 6 6Seal 201 492 02 81 1 1Bolt 000931 008248 2 2Nut 999901 008005 2 2Bracket 12949221 41 1 1Tensioning plate 1294900044 1 1Nut 1299900458 2 2Ignition co" (optionally) 000 1585703 2 2

000 1586503EZl ignitIon control Unit 012 545 83 32 - 1EZL ignitioncontrol unit 0125458532 1 -Coupling (CO potentiometer) 007 545 75 28 1 1Rubber grommet 000 546 60 35 1 1Flat connector terminal 002545 1926 3 3Flat connector terminal (small) 00354551 26 1 1Engine data information plate 14058441 17 1 1Cable 0.75 mm ge;gn 1050 mm comm. available 1 1Cable 0.75 mm brows 700 mm comm. available 1 1Insulating hose 0 4 mm 1700 mm comm. available 1 1