Catalytic Converter: Service and Repair

Removing And Installing Exhaust Manifold (With Primary Catalytic Converter)

Tools







Technical values







Preliminary work

DANGER:
- Vehicle raised incorrectly.
- Danger of fatal injury or material damage should the vehicle fall down.
- Raise the vehicle at the prescribed jacking points.
- Parts of the exhaust system become extremely hot.
- Danger of burns
- Permanent scarring of the skin
- Do not begin work until the exhaust system has cooled down completely.
- If it is imperative that you work on the hot exhaust system, ensure that you wear fire-resistant and heat-resistant protective gear.

1. Remove rear underbody cover.
2. Remove rear wheel. Use the specified special tool socket wrench insert 300 to avoid damaging the wheel rims.
3. Remove heat protection for brake hose. Unscrew two plastic nuts and one tapping screw and remove component.
4. Remove oxygen sensors.







5. Unscrew three M8 lock nuts on the triangular flange of the exhaust manifold and remove metal seal.

Removing exhaust manifold







1. Remove the exhaust manifold. Unscrew six hexagon-head bolts (M8 x 26) -Arrows- on the cylinder head. Get another person to hold the component if necessary.







2. Remove exhaust manifold (with primary catalytic converter) -3- and flange gasket -2-.

Installing exhaust manifold

INFORMATION:
- Always replace exhaust manifold screws during installation.
- Replace lock nuts.
- Replace gaskets.

1. Clean sealing surfaces on manifold flange and cylinder head using a brass wire brush for example.
2. Replace manifold seal -2- . Check that it is installed correctly - locating studs and beads must point to the cylinder head.
3. Fit exhaust manifold (with primary catalytic converter) -3- on the cylinder head and triangular flange with new metal seals. Get another person to help if necessary.












4. Position six new hexagon-head bolts (M8 x 26) -Arrows- by hand and tighten them from the inside outwards. Tightening torque: 23 Nm (17 ftlb.)

Subsequent work







1. Secure triangular flange for exhaust manifold using three new M8 lock nuts. Tighten nuts evenly. - Tightening torque: 23 Nm (17 ftlb.)
2. Install oxygen sensors.
3. Fit heat protection for brake hose using two plastic nuts and one tapping screw. Tighten nuts and screw carefully.
4. Fit rear wheel. Use the specified special tool socket wrench insert 300 to avoid damaging the wheel rims.
5. Install rear underbody cover.