Catalytic Converter: Service and Repair

Front Exhaust Pipe with Catalytic Converter

Special tools, testers and auxiliary items required

• Torque wrench 5-50 Nm (VAG 1331)

• Hot bolt paste (G 052 112 A3)

Removing





- Disconnect the Heated Oxygen Sensor (HO2S) electrical connector - arrow - and free up the wiring harness.





- From the top, remove the nuts - arrows - on the connection of the front exhaust pipe connection to the turbocharger.

- Remove the noise insulation..

- Remove nuts accessible from below for the front exhaust pipe to the turbocharger connection.

- Remove the nuts - arrows - and slightly pull the underbody cover downward.





With Engine Code CBFA





- Unclip the wires - arrows -, remove the bracket - 2 - and disconnect the electrical connectors - 1 and 3 -.

With Engine code CCTA





- Disconnect the electrical connector - arrow - on the underbody.

- Remove the electrical connector out of the bracket and free up the electrical wire to the oxygen sensor.

Continuation for All Engine Codes





- Remove the exhaust system suspended mount - arrows -.

- Remove the front tunnel bridge to underbody nuts - arrows - and bridge.





CAUTION!
Danger of damaging the decoupling element:

• Decoupling element must not be bent more than 10 degrees.

• Do not load decoupling element on cable.

• Do not damage wire mesh at decoupling element.

- Loosen the clamping sleeve - 1 - and push it rearward.

- Remove the front exhaust pipe with catalytic converter.

Installing

• Tightening specifications, refer to --> [ Exhaust System Assembly Overview ] Exhaust System Assembly Overview.

• Tunnel bridge to underbody nuts: 25 Nm

Install in reverse order of removal. When doing this note the following:

• Replace gaskets and self locking nuts.

• Coat the stud bolts on the exhaust manifold with hot bolt paste (G 052 112 A3).

• Align the exhaust system free of stress. Refer to --> [ Exhaust System, Aligning Free of Tension ] Exhaust System, Aligning Free of Tension.

• Exhaust system, checking for leaks. Refer to --> [ Exhaust System, Checking for Leaks ] Testing and Inspection.