Removing and Installing Primary Catalytic Converter

Removing And Installing Primary Catalytic Converter

Tools







Preliminary work

Preliminary work: Removing primary catalytic converter







NOTE: Please read the most important working regulations and warning notes.

ATTENTION:
Danger of burns from hot exhaust system.
- Only remove the exhaust system once it has cooled down.
- Wear protective gloves.

1. Move bonnet to service position using bonnet stay 9704.
2. Disconnect battery.
3. Put on the protection covers.
4. Remove right-hand engine compartment covers.
5. Pull the design cover up and off.







6. Remove main catalytic converter.

Removing primary catalytic converter

NOTE:
- All seals and fastening nuts for the primary catalytic converter must be replaced.
- Cable plugs 1 and 2 belong to the oxygen sensors behind catalytic converter, while plugs 3 and 4 belong to the oxygen sensors in front of catalytic converter. The colors of the cable plugs are the same for each exhaust assembly.

1. Disconnect all oxygen sensor cable plugs -1, 2, 3 and 4- and release cable from support.







NOTE: Mark oxygen sensors as you unscrew them so that the oxygen sensors are not confused.

2. Unscrew all oxygen sensors (a/f 22) (this gives more room for removing the primary catalytic converter).
3. Remove M8 fastening screw on sheetmetal bracket next to starter -arrow-.







4. Unscrew all fastening nuts between primary catalytic converter and exhaust manifold.







5. Remove starter catalyst in a downward direction.
6. Remove all seals and clean sealing surfaces.

Installing primary catalytic converter

NOTE: The sheetmetal lugs of the flange seals must be pointing downwards.

1. Clean all sealing surfaces and replace seals.







2. Fit new flange seals for the exhaust manifold over the studs of the exhaust manifold.
3. Get a helper to assist in moving the starter catalyst into installation position. When doing so, make sure that the studs of the exhaust manifold are inserted into the bores of the starter catalyst. Place new M8 fastening nuts on the studs of the exhaust manifold and an M8 fastening screw on the sheetmetal bracket next to the starter.
4. Tighten fastening nuts on exhaust manifold bolts. Tightening torque: 17 ftlb.







5. Tighten fastening screw on sheetmetal holder beside starter. Tightening torque: 17 ftlb.







6. Connect the battery.

Subsequent work

Subsequent work: Installing primary catalytic converter
1. Install main catalytic converter.
2. Install all oxygen sensors and oxygen sensor cables.
3. Fit engine compartment covers on the right.
4. Fit the design cover.