Catalytic Converters and Mufflers, Assembly Overview

Catalytic Converters and Mufflers, Assembly Overview

Catalytic Converters





1 Bolt

• 23 Nm

2 Suspended mount

• Replace if damaged

3 Catalytic converter, primary

• With flex joint

• Decoupling element must not be bent more than 10 degrees - otherwise it may be damaged

• Protect from shocks and impact stress

• Removing and installing => [ Primary Catalytic Converters ] Primary Catalytic Converters.

• Install exhaust system free of stress => [ Exhaust System, Installing ] Service and Repair.

4 Oxygen Sensor (O2S) 2 behind Three Way Catalytic Converter (TWC) (G131)

• Threads of new oxygen sensors are coated with assembly paste

• If reusing oxygen sensor, coat thread with hot bolt paste, hot bolt paste

• Assembly paste or hot bolt paste must not get onto slots of sensor body.

5 Nut

• Replace

• 23 Nm

6 Gasket

• Replace

7 Exhaust manifold

• Removing and installing => [ Exhaust Manifold ] Exhaust Manifold.

8 Heated Oxygen Sensor (HO2S) 2 (G108) (in front of catalytic converter)

• Threads of new oxygen sensors are coated with assembly paste

• If reusing oxygen sensor, coat thread with hot bolt paste, hot bolt paste

• Assembly paste or hot bolt paste must not get onto slots of sensor body.

9 Gasket

• Replace

10 Bolt

• 23 Nm

11 Catalytic converters, main

• Protect from shocks and impact stress

• Removing and installing => [ Main Catalytic Converters ] Main Catalytic Converters

• Install exhaust system free of stress => [ Exhaust System, Installing ] Service and Repair

• Individual mounting components to transmission => [ Suspended Mount to Transmission ]

12 Suspended mount

• Replace if damaged

13 Bolt

• 23 Nm

Mufflers





1 Nut

• 60 Nm

2 End pipe

• Replacing => [ End Pipe ] Service and Repair.

3 Bolt

• 23 Nm

4 Suspended mount

• Replace if damaged

5 Muffler, rear

• Original equipment as one unit with center muffler. For repairs, replace each separately.

• Separating point => [ Separate exhaust pipe at a right angle at
separating point using. ] Center and Rear Mufflers, Separating.

• Install exhaust system free of stress => [ Exhaust System, Installing ] Service and Repair.

6 Nut

• 23 Nm

7 Clamping sleeve, front

• Installed location => [ Installed Position of Front Double Clamps ]

• Before tightening, align exhaust system tension-free => [ Exhaust System, Installing ] Service and Repair.

• Tighten threaded connections evenly.

8 Muffler, center

• Original equipment as one unit with rear muffler. For repairs, replace each separately.

• Separating point => [ Separate exhaust pipe at a right angle at
separating point using. ] Center and Rear Mufflers, Separating.

• Install exhaust system free of stress => [ Exhaust System, Installing ] Service and Repair.

9 Suspended mount

• Replace if damaged

10 Bolt

• 23 Nm

11 Nut

• 23 Nm

12 Clamping sleeve, rear

• For individual replacement of center and rear mufflers

• Installed location => [ Installed Position of Rear Double Clamps ]

• Before tightening, align exhaust system tension-free => [ Exhaust System, Installing ] Service and Repair.

• Tighten threaded connections evenly.

Installed Position of Front Double Clamps





- Install clamping sleeves so threaded connections are below.

• Ends of bolts point toward outside of vehicle.

Installed Position of Rear Double Clamps





- Install left clamping sleeve so the threaded connections are at the left.

• Ends of bolts point down.

- Install right clamping sleeve so threaded connections are at top.

• Ends of bolts point toward right.

Suspended Mount to Transmission





1. Suspended mount

2. Bolt - 23 Nm

3. Nut - 23 Nm