Catalytic Converter: Service and Repair

Catalytic Converter, Removing And Installing

Removing







- Remove engine cover - arrows - .







- Remove coolant expansion tank - arrow - and set it aside with coolant hoses attached.







- Disconnect electrical connector - 1 - for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29 (brown connector) and free up electrical wiring to catalytic converter.
- Disconnect electrical connector - 2 - for Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19 (black connector) and free up electrical wiring to catalytic converter.







- Disconnect intake hose - 1 - for air filter/turbocharger.
- Disconnect electrical harness connector - 2 - at Mass Air Flow (MAF) Sensor G70.
- Free up wiring harness on air filter housing and remove air filter housing - 3 -.

NOTE: Exhaust system decoupling element must not be bent more than 10 degrees, otherwise it may be damaged.







- Loosen clamping sleeve - arrow - and push it rearward.







- Separate front exhaust pipe/catalytic converter - arrows - .
- Remove bolt - 1 - at bracket for front exhaust pipe and remove front exhaust pipe.







- Remove nut - arrow - at catalytic converter/turbocharger from below.







- Remove nuts - arrows - at catalytic converter/turbocharger from above.
- Take catalytic converter up and out.

Installing
Installation is in reverse order of removal, note the following:

NOTE: Replace gaskets and self-locking nuts.

- Install exhaust system free of stress.

Torque specifications

Catalytic converter to turbocharger 40 Nm 1) 2)
Mount to subframe 23 Nm
Clamping sleeve 23 Nm

1) Replace bolt or nut
2) Coat studs of exhaust manifold and threads of oxygen sensor with hot bolt paste