Removing And Installing Primary Catalytic Converter On DFI Engines
Primary Catalytic Converter On 4.8-litre V8 DFI Engines
Technical values
Preliminary work
1. Remove engine compartment cover above the oxygen sensor connectors.
2. Remove main catalytic converter.
Removing primary catalytic converter
Removing primary catalytic converter on cylinder bank 1-4
CAUTION: Danger of burns from hot exhaust system
- Do not remove the exhaust system until it has cooled down.
- Wear protective gloves.
1. Disconnect the oxygen sensor connector for the oxygen sensor behind the catalytic converter at the water splash panel (follow cable routing) and unclip the cables from the holder.
2. Expose oxygen sensor cable -1- and route it down to the primary catalytic converter.
3. Remove sheetmetal holders for the primary catalytic converter -7, 8, 10-.
CAUTION:
Studs and nuts not loosened correctly
- Studs break off exhaust manifold
- Replace damaged exhaust manifold.
- Spray the studs and nuts on the exhaust manifold with compressed air to clean them, then spray on antirust agent and leave it to take effect before loosening them.
- Loosen nuts carefully. Loosen the nuts by carefully turning them back and forth if they are very stiff.
4. Carefully loosen the flange nuts using a change-over ratchet and several extensions. -2-. - Flange bolts securing primary catalytic converter to exhaust manifold
1 bis 5 - Tightening sequence for nuts
CAUTION:
Projecting ceramic catalytic converter
- Risk of damage to ceramic catalytic converter
- Ensure that your work area is well illuminated.
- Carefully guide the projecting ceramic catalytic converter past the studs on the exhaust manifold.
- Cover and store the ceramic monolith for the primary catalytic converter in a safe place until you are ready to install it.
- Protect the ceramic monolith from damage while you are working on the primary catalytic converter. If there are deep cracks or large chips, replace the primary catalytic converter. Slight superficial damage will not impair its function.
5. Carefully remove the primary catalytic converter with the help another worker.
6. Remove sheetmetal seal -4-. Clean sealing faces.
Removing primary catalytic converter on cylinder bank 5-8
CAUTION: Danger of burns from hot exhaust system
- Do not remove the exhaust system until it has cooled down.
- Wear protective gloves.
1. Disconnect the oxygen sensor connector for the oxygen sensor behind the catalytic converter at the water splash panel (follow cable routing) and unclip the cables from the holder.
2. Expose oxygen sensor cable -1- and route it down to the primary catalytic converter.
3. Remove heat shield on the cardan joint of the steering column. -arrows-
4. Unscrew two coolant pipe screws on the converter bell housing -arrow-. Loosen the coolant pipe.
5. Remove sheetmetal holders for the primary catalytic converter -6, 7, 10-
CAUTION:
Studs and nuts not loosened correctly
- Studs break off exhaust manifold
- Replace damaged exhaust manifold.
- Spray the studs and nuts on the exhaust manifold with compressed air to clean them, then spray on antirust agent and leave it to take effect before loosening them.
- Loosen nuts carefully. Loosen the nuts by carefully turning them back and forth if they are very stiff.
6. Carefully loosen the flange nuts using a change-over ratchet and several extensions. -2- - Flange bolts securing primary catalytic converter to exhaust manifold
1 bis 5 - Tightening sequence for nuts
CAUTION:
Projecting ceramic catalytic converter
- Risk of damage to ceramic catalytic converter
- Ensure that your work area is well illuminated.
- Carefully guide the projecting ceramic catalytic converter past the studs on the exhaust manifold.
- Cover and store the ceramic monolith for the primary catalytic converter in a safe place until you are ready to install it.
- Protect the ceramic monolith from damage while you are working on the primary catalytic converter. If there are deep cracks or large chips, replace the primary catalytic converter. Slight superficial damage will not impair its function.
7. Carefully remove the primary catalytic converter with the help of another worker.
8. Remove sheetmetal seal -4-. Clean sealing faces.
Installing primary catalytic converter
Installing primary catalytic converter on cylinder bank 1-4
1. Ensure sealing faces of exhaust system are clean.
2. Replace flange gasket -4- and slide it over the studs on the exhaust manifold -5-.
CAUTION:
Projecting ceramic catalytic converter
- Risk of damage to ceramic catalytic converter
- Ensure that your work area is well illuminated.
- Carefully guide the projecting ceramic catalytic converter past the studs on the exhaust manifold.
- Cover and store the ceramic monolith for the primary catalytic converter in a safe place until you are ready to install it.
- Protect the ceramic monolith from damage while you are working on the primary catalytic converter. If there are deep cracks or large chips, replace the primary catalytic converter. Slight superficial damage will not impair its function.
3. Carefully move primary catalytic converter into installation position.
4. Fit new fastening nuts between the exhaust manifold and primary catalytic converter, but leave them loose.
5. Make sure that the sheetmetal holder for the primary catalytic converter fits correctly on the exhaust manifold after you tighten the nuts -8-.
6. Fit fastening screw on catalytic converter holder and nuts to the specified tightening torque and according to the specified tightening sequence - Flange bolts securing primary catalytic converter to exhaust manifold. For details of tightening torque for transmission bolts.
- Tightening torque: 23 Nm (17 ftlb.)
- Tightening torque: 23 Nm (17 ftlb.)
1 bis 5 - Tightening sequence for nuts
CAUTION: Danger of fire and material damage.
- Lay the oxygen sensor cable so that it cannot touch the exhaust manifold.
7. Route oxygen sensor cable and clip into position. -1-.
8. Plug in the connector for the oxygen sensor behind the catalytic converter at the water splash panel.
Installing primary catalytic converter on cylinder bank 5-8
CAUTION: Danger of fire and material damage.
- Lay the oxygen sensor cable so that it cannot touch the exhaust manifold.
CAUTION:
Projecting ceramic catalytic converter
- Risk of damage to ceramic catalytic converter
- Ensure that your work area is well illuminated.
- Carefully guide the projecting ceramic catalytic converter past the studs on the exhaust manifold.
- Cover and store the ceramic monolith for the primary catalytic converter in a safe place until you are ready to install it.
- Protect the ceramic monolith from damage while you are working on the primary catalytic converter. If there are deep cracks or large chips, replace the primary catalytic converter. Slight superficial damage will not impair its function.
1. Ensure sealing faces of exhaust system are clean.
2. Replace flange gasket -4- and slide it over the studs on the exhaust manifold -5-.
CAUTION:
Projecting ceramic catalytic converter
- Risk of damage to ceramic catalytic converter
- Ensure that your work area is well illuminated.
- Carefully guide the projecting ceramic catalytic converter past the studs on the exhaust manifold.
- Cover and store the ceramic monolith for the primary catalytic converter in a safe place until you are ready to install it.
- Protect the ceramic monolith from damage while you are working on the primary catalytic converter. If there are deep cracks or large chips, replace the primary catalytic converter. Slight superficial damage will not impair its function.
3. Carefully move primary catalytic converter into installation position.
4. Fit new fastening nuts between the exhaust manifold and primary catalytic converter, but leave them loose.
5. Make sure that the sheetmetal holder for the primary catalytic converter fits correctly on the exhaust manifold after you tighten the nuts -8-.
6. Fit fastening screw on catalytic converter holder and nuts to the specified tightening torque and according to the specified tightening sequence - Flange bolts securing primary catalytic converter to exhaust manifold. For details of tightening torque for transmission bolts,
- Tightening torque: 23 Nm (17 ftlb.)
- Tightening torque: 23 Nm (17 ftlb.)
1 bis 5 - Tightening sequence for nuts
CAUTION: Danger of fire and material damage.
7. Route oxygen sensor cable and clip into position. -1-.
8. Fit heat shield on the cardan joint of the steering column. -arrows-
- Tightening torque: 10 Nm (7.5 ftlb.)
9. Fit coolant pipe on converter bell housing -arrow-.
10. Plug in the connector for the oxygen sensor behind the catalytic converter at the water splash panel.
Subsequent work
1. Install main catalytic converter.
2. Fit engine compartment cover above the oxygen sensor connectors.