Catalytic Converter: Service and Repair

Removing And Installing Both Exhaust Manifolds With Catalytic Converter

Special Tools Required:
00 0 200
00 0 201
00 0 202
00 0 204
00 0 206

Remove reservoir for windshield cleaning system.
Remove suction-filter housing.





Prepare special tool 00 0 200 comprising special tools 00 0 201 /00 0 202 /00 0 204 /00 0 206 .





Caution!
Risk of damage.
Do not damage lines, cables or hoses.

Version with air conditioning:
A/C system lines remain connected.
Detach drier bottle on mounting to body.
Place special tool 00 0 206 on engine carrier.





Carefully lift engine approx. 5 mm.





Remove cover from injection valves.

Caution! Do not mix up oxygen monitor sensors for cylinders 1 to 3 and 4 to 6 at plug connection to wiring harness.

Mark plug connections.
Unclip the cable from the retainer.
Disconnect plug connection.
Unclip cable on rear side of engine from cable guide.

Remove engine splash guard.
Remove exhaust system.

Note: The oxygen sensors are in danger of being damaged when the exhaust manifolds are removed and installed.

Remove oxygen monitor sensors.
Remove oxygen control sensors.

Remove right engine support arm from engine block.
Remove right engine mount from front axle support.

Note: Rear exhaust manifold with catalytic converter can only be removed after front exhaust manifold with catalytic converter has first been removed.

Remove front exhaust manifold with catalytic converter.
Remove rear exhaust manifold with catalytic converter.

Installation:
Clean sealing faces, replace gaskets.
Coat thread with copper paste -CRC-.
Replace nuts.
Tightening torque, refer to Specifications, Mechanical.