Catalytic Converter: Service and Repair

Three-way catalytic converter (TWC), replacing

Special tools:
999 5972 FIXTURE 999 5972 Fixture

Removing catalytic converters

Preparation




Raise the car.

Remove
- the left front wheel
- the splash guard under the engine
- the rear SIPS member
- the nuts for the rear flange seal on the catalytic converter
- the nuts for the front flange seals on the catalytic converters
- expose the heated oxygen sensor (HO2S) wiring. Disconnect the connectors.
Disconnect the brake pipe from its holder on the front SIPS member.

Removing catalytic converters




Position a mobile jack with universal plates 999 5972 FIXTURE 999 5972 Fixture under the catalytic converters.
Remove the screws for the front SIPS member.
Pull back and lower the catalytic converters with their heat deflector plates.

Note! The routing of the heated oxygen sensor (HO2S) wiring over the brake pipe.

Installing three-way catalytic converters (TWC)

Transferring components when replacing catalytic converters




Remove the holders for the rear heated oxygen sensors (HO2S) wiring holders.
Lift out the heat deflector plate.
Remove the heated oxygen sensors (HO2S).
Remove the three-way catalytic converter (TWC) mountings and the SIPS member.

Install
- the mountings and SIPS member on the new three-way catalytic converter (TWC)
- the heated oxygen sensors (HO2S). Tighten to 45 Nm.

Note! Lubricate the thread using paste, P/N: 116 1408.

Position the heat deflector plate.
Press the rear heated oxygen sensors (HO2S) holders into place.

Note! Handle the new three-way catalytic converter (TWC) boot carefully. It is sensitive to twisting.

Installing the catalytic converter unit with the heat deflector plate




Use new nuts and gaskets.

Note! Lubricate all the studs. Use paste, P/N: 116 1408. Avoid skin contact with the paste.

Connect the pipe to the engine. Use a mobile jack with universal plate 999 5972 FIXTURE 999 5972 Fixture as support.

Note! Ensure that the heated oxygen sensor (HO2S) wiring is above the brake pipe.

Press the brake pipe into place in its holder on the front SIPS member.
Connect to the rear exhaust pipe. Install all nuts loosely.
Install the screws for the front SIPS member.
Remove the mobile jack.

Tighten
- the nuts for the front flange seal. Tighten crosswise to 25 Nm
- the front SIPS member. Tighten to 25 Nm
- the rear flange seal nuts. Tighten to 25 Nm
- the rear SIPS member. Tighten to 25 Nm.




Connect the heated oxygen sensor (HO2S) wiring.
Secure the wiring at the rear edge of the sub-frame.
Install the splashguard under the engine.
Install the left front wheel. See Installing wheels Service and Repair.

Carry out a function test
Test start the engine and check for leakage.