Three-Way Catalytic Converter - Replacing
SECTION2
GROUP
25
NO.
816
DATE
July 1996
Replacing exhaust system and three-way catalytic converter (TWC)
850AWD 1997-
Canadian cars only
REFERENCE: TP 4314201, SECTION 4(43,46) AWD (ALL WHEEL DRIVE); 850 1997-
Replacing exhaust system and three-way catalytic converter (TWC)
Replacing exhaust system and three-way catalytic converter (TWC).
Special tools: 999 5304-4, 999 5504-9, 999 5561-9, 999 5652-6
Removing exhaust system
AA1
Tail pipe and muffler
Caution!
This operation must be performed by two people.
Removing:
Raise the car.
Remove exhaust pipe clamp (1) at rear axle.
The clamp secures the joint between the front and rear exhaust system.
Spray the rubber eyelets (2) with lubricant.
Unhook and lift off the rear system.
The two mufflers and the intermediate pipe are one unit.
Front section with three-way catalytic converter (TWC)
AA2
Removing
To access the exhaust pipe flange by the turbocharger (TC), the bevel gear coupling flange must be removed.
Carry out work with the car raised.
Mark the position of the propeller shaft flange in relation to the bevel gear flange.
Remove propeller shaft screws.
Use counterhold 999 5561-9.
AA3
Lower propeller shaft
Remove two propeller shaft center bearing bracket screws from member.
Remove left member screws.
Remove right screws.
Move propeller shaft to the right and secure at the front.
Let the propeller shaft rest on the member.
AA4
Mark flange
Mark flange in relation to the end of the pinion.
Remove nut.
Use counterhold 999 5652-6.
AA5
Remove flange
Remove:
- Flange. Use separator 999 5304-4.
AA6
Remove nuts at exhaust pipe flange
Lower car and remove:
- Heat deflector plate above turbocharger (TC).
- Pulsed secondary air injection system (PAIR) pipe. Lubricate nut.
- Nuts on exhaust pipe flange to turbocharger (TC). Lubricate studs so that they are not pulled out.
- Heated oxygen sensor (HO2S) connectors.
AA7
Lift down front exhaust system
Raise the car
Remove heated oxygen sensor (HO2S) cable clips.
Remove exhaust pipe mounting on bevel drive.
Open the clamp holding the front pipe to the intermediate pipe.
Spray the rubber eyelets with lubricant.
Unhook and lift down exhaust pipe with three-way catalytic converter (TWC).
Replace front exhaust pipe
Move heated oxygen sensors (HO2S) to new three-way catalytic converter (TWC).
Transfer or replace heat shield.
Lubricate threads with screw compound P/N: 1161408-8.
Tighten heated oxygen sensors (HO2S) to 45 Nm (33 ft.lbs).
AA8
Intermediate pipe
Removing intermediate pipe
Raised car, remove:
- clamp between front system and intermediate pipe.
- clamp between intermediate pipe and rear system.
Lift down pipe.
AA9
Replace the front system
Hang up the front system:
Lubricate all screw joints with thread sealant P/N: 1161035-9.
Lift up and locate front pipe, use new bolts.
Tighten pulsed secondary air injection system (PAIR) pipe.
Screw mounting on bevel gear into place without tightening.
Hook on rubber eyelets.
Tighten screwed joints:
- torque 30 Nm (22 ft.lbs) for Turbo - exhaust pipe
- torque 40 Nm (30 ft.lbs) for M10 bevel gear Secure heated oxygen sensor (HO2S) wiring. Install new cable clips if necessary.
Route cables from heated oxygen sensors (HO2S) and connect connectors.
Note!
A poorly secured cable can be a fire risk. Take care when securing cables by the engine and especially next to the turbocharger (TC) and exhaust system.
AA1O
Reinstall flange.
Install pinion flange as marked.
Use a press tool 999 5504-9 if necessary.
AA11
Install nut
Install a new lubricated nut, there must be no axial play.
Tighten to 180-200 Nm (133-148 ft.lbs).
Use counterhold 999 5652-6.
Note!
Tightening torque 200 Nm (148 ft.lbs) must not be exceeded.
The forces on the pinion bearing may become too great, causing it to seize.
AA12
Reinstall propeller shaft
Install propeller shaft to flange as marked. Use new screws.
Tighten screws crosswise to 8 Nm (6 ft.lbs) the crosswise to 30 Nm (22 ft.lbs).
Start tightening with the same screw both times.
Use counterhold 999 5561-9.
AA13
Reinstall center bearing member and bracket
Install center bearing member to body. Tighten to 25 Nm (18 ft.lbs).
Install center bearing bracket to member. Tighten to 25 Nm (18 ft.lbs).
Reinstall heat deflector plate above turbocharger (TC).
AA14
Install intermediate pipe
Install intermediate pipe and locate front joint clamp without tightening screws.
AA15
Install rear pipe with muffler
Hang system in eyelets and adjust intermediate pipe and clamp.
Adjust and tighten clamp at rear axle and clamp between front system and intermediate pipe.
Tightening torque: 25 Nm (18 ft.lbs).
Note!
Check that heat deflector plates are correctly positioned exhaust system secured and that the clearance between the exhaust system and adjacent components is at least 20 mm (3/4"). Especially by the fuel tank.