Removing and Installing Primary Catalytic Converter

Removing And Installing Primary Catalytic Converter

Preliminary work
1. Remove engine compartment cover above the oxygen sensor connectors.
2. Remove wheel.
3. Remove front wheel housing liner.
4. Remove air cleaner housing.
5. Remove main catalytic converter.

Removing primary catalytic converter

Removing primary catalytic converter, cylinder bank 1 - 4

ATTENTION:
Danger of burns from hot exhaust system
- Do not remove the exhaust system until it has cooled down.
- Wear protective gloves.

NOTE: Observe the most important working regulations and warning notes.







1. At the water splash panel, disconnect the connector for the oxygen sensor behind catalytic converter and unclip cable from support.







2. With the aid of a mirror, remove the fastening screw on the catalytic converter bracket -arrow lower right-.







3. Remove the three fastening nuts between the exhaust manifold and primary catalytic converter.







4. Release oxygen sensor cable and remove primary catalytic converter in a downward direction. Remove flange gasket.

Removing primary catalytic converter, cylinder bank 5 - 8

ATTENTION:
Danger of burns from hot exhaust system
- Do not remove the exhaust system until it has cooled down.
- Wear protective gloves.

NOTE: Observe the most important working regulations and warning notes.







1. At the water splash panel, disconnect the connector for the oxygen sensor behind catalytic converter and unclip cable from support.







2. With the aid of a mirror, remove the fastening screw on the catalytic converter bracket -arrow lower right-.







3. Remove the three fastening nuts between the exhaust manifold and primary catalytic converter.







4. Release oxygen sensor cable and remove oxygen sensor.
5. Lower starter catalyst clear. Remove flange gasket.

Installing primary catalytic converter

Installing primary catalytic converter, cylinder bank 1 - 4

NOTE:
- Observe the most important working regulations and warning notes.
- Metal seals and self-locking nuts and bolts must always be replaced.

1. Ensure sealing faces of exhaust system are clean.
2. Replace flange gasket and push over the studs of the primary catalytic converter.
3. Place primary catalytic converter in installation position.
4. Through the wheel housing, position fastening screw on catalytic converter bracket.
5. Position the three fastening nuts between the exhaust manifold and primary catalytic converter.







6. Tighten fastening screw to catalytic converter bracket and nuts to specified tightening torque. Tightening torque: 17 ftlb. Tightening torque: 17 ftlb.

ATTENTION:
Danger of fire and material damage.
- Lay the oxygen sensor cable so that it cannot touch the exhaust manifold.

7. Lay cable of oxygen sensor and clip it in.
8. At the water splash panel, connect the connector for the oxygen sensor behind catalytic converter.







Installing primary catalytic converter, cylinder bank 5 - 8

NOTE:
- Observe the most important working regulations and warning notes.
- Metal seals and self-locking nuts and bolts must always be replaced.

1. Ensure sealing faces of exhaust system are clean.
2. Replace flange gasket and push over the studs of the primary catalytic converter.
3. Install oxygen sensor.
4. Place primary catalytic converter in installation position.
5. Position the three fastening nuts between the exhaust manifold and primary catalytic converter.







6. Through the wheel housing, position fastening screw on catalytic converter bracket -lower right screw-.







7. Tighten fastening screw to catalytic converter bracket and nuts to specified tightening torque. Tightening torque: 17 ftlb. Tightening torque: 17 ftlb.

ATTENTION:
Danger of fire and material damage.
- Lay the oxygen sensor cable so that it cannot touch the exhaust manifold.

8. Lay cable of oxygen sensor and clip it in.
9. At the water splash panel, connect the connector for the oxygen sensor behind catalytic converter.







Subsequent work
1. Install main catalytic converter.
2. Install air cleaner housing.
3. Install front wheel housing liner.
4. Mount wheel.
5. Fit engine compartment cover above the oxygen sensor connectors.