Disassembly, Cleaning & Inspection, Reassembly

DISASSEMBLY

Pipe Joint:

Downpipe Catalytic Converters
- Remove the nut, bolt and washer (1) from the clamping ring (downpipe catalytic converters to intermediate pipe). Open the clamp if necessary and slide it onto the intermediate pipe.
- Carefully separate the downpipe converters assembly from the intermediate pipe (2).
- Remove the clamp from the intermediate pipe and remove the olive (3).

Rear Converter Joint:

Underfloor Catalytic Converters
- Remove the nut, bolt and washers from the right hand side clamping ring (1) (underfloor catalytic converters to intermediate pipe). Open the clamp (2) if necessary and slide it onto the intermediate pipe.
- Carefully separate the converter (3) from the intermediate pipe.
- Remove the clamp from the intermediate pipe.
- Repeat the above instructions for the left hand side underfloor converter.

Cleaning and Inspection
- For parts which are intended for re-use, clean the sealing faces, clamps and olives; inspect for cracks and deep pitting.
- Renew as necessary.
- Obtain new locking nuts prior to assembly.

REASSEMBLY

Downpipe Catalytic Converters
- Check for and remove any debris from inside the downpipe and intermediate pipe assemblies.
- Fit the clamping ring over the front section of the intermediate pipe.
- Apply exhaust sealant to the outer surface of the olive.
- Fit the olive and assemble the downpipe catalytic converter to the intermediate pipe.
- Position the clamping ring over the joint and fit the retaining bolt, washers and Helicoil locking nut.
- Tighten the clamp bolt sufficiently to hold the assembly together.

Underfloor Catalytic Converters
- Check for and remove any debris from inside the underfloor catalytic converter pipes and intermediate pipe assemblies.
- Fit the clamping ring over the right hand rear section of the intermediate pipe.
- Apply exhaust sealant sparingly to approximately 1 inch of the outer surface at the end of the intermediate pipe. Do not apply sealant to the inner surface of the catalytic converter pipe.
- Fit the catalytic converter to the intermediate pipe. Position the clamping ring over the joint and fit the retaining bolt, washers and steel locking nut.
- Tighten the clamp bolt sufficiently to hold the assembly together.
- Repeat the above instructions for the left hand underfloor converter.