Catalytic Converter: Service and Repair

Note:
To remove the exhaust manifolds, you must lower the front axle support.
There is no need to perform a front axle alignment check.





Assemble special tool 00 0 200 with special tool 00 0 201 /00 0 202 / 00 0 204 / 00 0 208 and install.
Secure special tool 00 0 200 to front suspension eye on engine.

Note: The supports (1) of special tool 00 0 208 must rest on the bolt connection of both side walls.





Tighten the screws (1 and 2).





Raise engine with special tool 00 0 200 approx. 5 mm.





Remove microfilter.
Open cable duct on lower section of microfilter housing (2) and feed out cable(s).
Release screws (1) and remove lower section of microfilter housing (2).





Remove cover from fuel injectors.

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. 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, refer to Powertrain Management.
Remove oxygen control sensors, refer to Powertrain Management.

Detach steering spindle from steering gear.
Detach retaining bracket for stabilizer bar on left and right from front axle support.
Unfasten top left and right nuts on engine mount.





As shown in illustration, support front axle support with a block of wood (1).

Note:
Steering gear remains bolted to front axle support.
Return hose of steering gear must not be overstretched when front axle support is lowered.

Release screw connection of front axle support and lower front axle support approx. 90 mm.
Installation instructions and tightening torques are described in the work step "Replacing front axle support".

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 threads with copper paste.
Replace nuts.
Tightening torque, refer to Specifications, Mechanical.