Removing and installing catalytic converter or front exhaust system

AR49.10-P-5531AV

Removing and installing catalytic converter or front exhaust system

17.11.05

 

Remove/install

1

Disconnect plug connection of left and right O2 sensors upstream of TWC (G3/3x1, G3/4x1)

AR14.00-P-5303A

2

Unscrew bolts (1) at flange connection between front exhaust system / exhaust manifold

 Loosen flange connection (6) or Disconnect if necessary.

If bolts are stiff, or thread damaged:

Replace the rivet nuts in the exhaust manifold.

AR49.10-P-5531-01DA



*BA14.10-P-1002-01B



*BA49.10-P-1002-01A

3

Unscrew bolts (3) at flange connection between front exhaust system / rear exhaust system

 Installation:

Replace nuts and bolts (3) if necessary.

4

Unscrew nuts (2) on bracket

 Installation: Install new nuts.

5

Remove front exhaust system with three-way catalytic converter (4)

 Removal/installation:

Push rear exhaust system back slightly, or disconnect rear exhaust system if necessary.

 Ensure that the heat shields of the exhaust system are not damaged when removing and installing the three-way catalytic converter (4).

 Check seal ring (5) for damage and replace if necessary.

Use emery cloth to remove combustion and corrosion residues at connection points.



*BA49.10-P-1002-01A



Notes on disposing of catalytic converters

Vehicles with three-way catalytic converter code 620a

OS49.10-P-1000-01A

6

Install in the reverse order

 Install catalytic converter free of stress.

Number

Designation

Engine
112 except 112.951/
976

Engines 113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/993/
995

BA14.10-P-1001-01B

Nut on exhaust manifold

Nm

16

16

BA14.10-P-1002-01B

Flange connection, exhaust manifold and front exhaust pipes

Nm

20

20

Number

Designation

Engines
112, 113
in model
202

Engines
112, 113
in model
208

BA49.10-P-1002-01A

Bolt, flange connection to exhaust pipe

Nm

20

20