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#1
03-11-2014, 12:29 PM
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1994 E420 Exhaust
Hi,
First off I searched the forums and the internet but could not find the answers I needed. I am changing my catalytic converter and the front muffler on a 1994 E420. The catalytic does not look like the original but the muffler does. The connections from the catalytic to the muffler are seized. The connections to the passenger side manifold and crossover pipe were in good condition. Now on to my questions. 1. Do I need any gaskets or seal rings for the manifold and crossover pipe connection from the catalytic? The old one had nothing there and there was always and exhaust smell in the car when idling. 2. The catalytic pipes to the muffler has only one flange so I know I need one for the other pipe but what kind of seals and/or gaskets do I need? Are they both the same? The connection between the old catalytic and muffler was completely gone and I could not make out what was there. Any help is greatly appreciated. Thanks. 
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#4
03-12-2014, 10:21 AM
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The seals / gaskets mentioned above are correct, however they are re-usable unless damaged. Separating the twin pipes at the back of the catalyst can be extremely difficult. The bolts may break, the link below shows part numbers for the photos. Note the 500E has a bolt-on rear muffler, the 400E does not.
Photos are at this link: http://www.w124performance.com/images/M119/exhaust/ 
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#5
03-12-2014, 04:47 PM
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Thanks. I am still confused on which seals go where. Here are the two that confuse me.
1994 Mercedes-Benz E420 Base Sedan - Exhaust Gaskets, Hardware, and Miscellaneous - Page 1 Part number 126-997-00-41 and 202-492-02-81. Do I need one of both or two of one? If one of both then which one goes where?
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#6
03-14-2014, 02:01 AM
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I just removed my muffler system between the cats and the front muffler. I had to use a slide hammer and WD-40 on the pipe for the passenger side because it was stuck. I was preparing to use a blow torch but didn't need it.
Looking at the picture, the passenger side compression ring appears to be embedded in the flange on the cat side (I didn't notice this until just now). GSXR is right, as usual--the 400E/E420 does not have a bolt-on rear muffler, even though the EPC shows it does.
__________________
1993 400E, 256,000 miles (totaled) 1994 E420, 200,000+ miles 1995 E420, 201,000 miles Last edited by emerydc8; 03-14-2014 at 02:12 AM.
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#7
03-14-2014, 10:56 AM
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The rear of the cat pipe has two different seals. 126-997-00-41 is the graphite "flat cylinder" seal. This one is almost always reusable. I've never had to replace one. The other one is 202-492-02-81, the same as used for the front crossover pipe. This one is often reusable as well, but can be damaged if you pry against it while trying to separate the cat pipe from the middle/rear pipe.
The 400E comes with a one-piece rear assembly where the resonator (middle muffler) and rear muffler are welded together. The replacement rear muffler is a slip-fit, not flanged... you cut the pipe, and slip the new muffler over the old pipe, and clamp it together. Completely different setup than the flanged muffler/resonator on the 500E. 
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#9
03-17-2014, 11:55 AM
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Just to wrap up things here I ended up using the following parts to install the catalytic converter.
Cat to passenger manifold -> No seal. Cat to crossover pipe -> Seal ring (part # 202-492-02-81) Cat to mid muffler (driver) -> Seal ring (part # 202-492-02-81) Cat to mid muffler (passenger) -> Seal ring (part #126-997-00-41) Cat to mid muffler (passenger) -> Flange I also ended up needing some bolts as they were really rusted and had to be cut out. Thanks for all the help.
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#11
03-19-2014, 08:42 AM
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WTB, Bosal 099-166 Catalytic Converter
I need to replace my Catalytic Converter on my E420. Can anyone advise me on the best place to purchase a Bosal 099-166.
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