Catalytic Converter: Service and Repair

Remove and installing catalytic converter or front exhaust system

Shown On Engine 113 In Model 203:

DANGER:
- Risk of death. Death may result if vehicle slips or topples from the lifting platform.
- Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

1 Jacking up and supporting vehicle
2 Remove engine compartment paneling
3 Separate left 02 sensor connector, upstream of TWC (G3/302x1) 02 and right 02 sensor connector, upstream of TWC (G3/4x1).

NOTE: Remove connectors from brackets.

4 Separate connector of left oxygen sensor, downstream TWC (G3/502x1) 02and connector of right oxygen sensor, downstream TWC (G3/6x1).

NOTE: Remove connectors from brackets.

5 Detach front exhaust system/three-way catalytic converter (1) from exhaust manifold.

CAUTION: Installation: replace bolts (2), as if they are used again, the connection may not be tight and the bolts may shear off. Inspect rivet nuts in exhaust manifold, replace if necessary, Replace rivet nuts in exhaust manifold.

6 Undo bracket (3) of exhaust system on transmission, to this end undo bolts (4).
7 Support rear exhaust system
8 Detach bracket (3) on front exhaust system/three-way catalytic converter (1) right and left

NOTE: Installation: Check threaded plate (5), replace if necessary. Replace nuts (6).

9 Push together bracket (3)

10 Separate front exhaust system/catalytic converter (1) from the rear exhaust system.

NOTE: Installation: check seal ring (7) for damage, replace if necessary. Use emery cloth to remove combustion and corrosion residues at connection points.

CAUTION: Replace bolts (8) and nuts (9), because if they are used again the connection may not be tight and the bolts can shear off.

11 Remove front exhaust system/catalytic converter (1)

NOTE:
- Push rear exhaust system to the rear for this step.
- Installation: install front exhaust system/three-way catalytic converter (1) free of tension.

12 Detach right catalytic converter (1a)

NOTE: Installation: Use emery cloth to remove combustion and corrosion residues at connection points. Install right three way catalytic converter (la) free of tension.

CAUTION: Replace bolts (10) and nuts (11), because if they are used again the connection may not be tight and the bolts can shear off.

13 Install in the reverse order.