Catalytic Converter: Service and Repair

Removing And Installing Catalytic Converter

Preliminary work
1. Remove air cleaner housing.










2. Disconnect the relevant plug connections for the oxygen sensors in the engine compartment.

NOTE: Always expose oxygen sensor wire far enough for it to be able to turn when unscrewing the sensor.

3. Expose oxygen sensor cable.

NOTE: If a catalytic converter needs to be replaced, first remove the two oxygen sensors.

4. Remove oxygen sensor behind catalytic converter so that it is not damaged when you remove the catalytic converter.

Removing catalytic converter

DANGER:
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.

Component overview










1. Screw off M8 fastening nuts on clamping sleeve and slide sleeve onto the silencer pipe. If corroded, spray sleeve with penetrating oil or heat it up.
2. Loosen clamp on catalytic converter holder.







3. Loosen threaded flange joint to exhaust manifold -1-. Replace lock nuts.
4. Lift catalytic converter out of the vehicle.

Installing catalytic converter

NOTE:
- Always expose oxygen sensor wire far enough for it to be able to turn when unscrewing the sensor.
- Replace clamping sleeve, seal and lock nuts. Apply a light coating of high-temperature grease on the sleeve before installation to facilitate fitting.

1. Grease new clamping sleeve with high-temperature paste and slide it onto the silencer pipe.
2. Insert catalytic converter into the vehicle. When doing so, watch out for the oxygen sensors and cable.

NOTE: Observe installation position of three-hole flange seal. The beading is facing the exhaust manifold and the edges must not project over the contour of the flange.

3. Fit new seal and new lock nuts on the exhaust manifold flange and screw on slightly.







4. Slide the clamping sleeve over the silencer pipe and move it to installation position - Installation position of clamping sleeve, then screw on the two hexagon nuts.







5. Tighten three lock nuts -1- on catalytic converter flange. Tightening torque: 23 (17 ft.lb.) Nm
6. Tighten fastening screws on clamping sleeve. Tightening torque: 23 (17 ft.lb.) Nm
7. Align clamp on catalytic converter holder and tighten M8 screw. Tightening torque: 23 (17 ft.lb.) Nm

Subsequent work

NOTE:
- Grease the thread of the oxygen sensors that will be fitted again with Optimal Optimally Paste MF.
- Replace sealing ring. If this is not possible, the "old" oxygen sensor must be tightened to 50 Nm (37 ft.lb.).

1. Install oxygen sensor behind catalytic converter. If the sensor ahead of the catalytic converter was also removed, install this as well.
2. Lay oxygen sensor cable carefully and connect cable plug.
3. Install air cleaner housing.