Remove and installing catalytic converter or front exhaust system

AR49.10-P-5531PV

Remove and installing catalytic converter or front exhaust system

17.11.05

 

Remove/install

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

1

Lift/jack up vehicle

AR00.60-P-1000P

2

Remove engine compartment paneling

AR61.20-P-1105P

3

Disconnect left O2S2 sensor connector upstream of TWC (G3/3x1) and right O2a2 sensor connector upstream of TWC (G3/4x1).

 Remove connectors from brackets.

4

Disconnect connector for left O2 sensor connector downstream of TWC (G3/5x1) and connector for right O2s sensor downstream of TWC (G3/6x1).

 Remove connectors from brackets.

5

Detach front exhaust system / catalytic converter at exhaust manifold

 Installation: Replace bolts (2) since the connection may not be tight or the bolts may shear off if they are used again. Check the rivet nuts in the exhaust manifold and replace them if required: 

Replace the rivet nuts in the exhaust manifold.

AR49.10-P-5531-01DA



*BA14.10-P-1002-01B

 Caulking bolt

*103589013900

6

Loosen bracket (3) for exhaust system on transmission by removing bolts (4)



*BA49.10-P-1007-01A

7

Support rear exhaust system.

8

Remove the brackets (3) of the front exhaust system/catalytic converter (1) on the right and on the left

 Installation: Check the tapping plate (5) and replace it if required. Replace nuts (6).



*BA49.10-P-1008-01A

9

Push together bracket (3)

10

Disconnect front exhaust system/catalytic converter (1) from rear exhaust system

 Installation: Replace bolts (8) and nuts (9) because if they are reused, the connection may not be tight and the bolts may shear off.

 Installation: Check the seal ring (7) for damage and replace it if required. Use emery cloth to clean connection points free of combustion and corrosion residues.



*BA49.10-P-1009-01A

11

Remove front exhaust system/catalytic converter (1)

 Push rear exhaust system to the rear for this step.

 Installation: Install front exhaust system (1) free of tension.

12

Remove right catalytic converter (1a)

 Installation: Replace bolts (10) and nuts (11) because if they are reused, the connection may not be tight and the bolts may shear off.

 Installation: Use emery cloth to remove combustion and corrosion residues at connection points. Install right catalytic converter (1) free of tension.



*BA49.10-P-1009-01A



Notes on disposing of catalytic converters

all

OS49.10-P-1000-01A

13

Install in the reverse order

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

Engine 113.987/
988/990/
991

BA14.10-P-1002-01B

Flange connection, exhaust manifold and front exhaust pipes

Nm

20

20

20

Number

Designation

Engines
112, 113
in model
203

Engines
112, 113
in model
209

BA49.10-P-1007-01A

Bolt, exhaust bracket to transmission

Nm

20

20

BA49.10-P-1008-01A

Self-locking nut on front exhaust pipe

Nm

20

20

BA49.10-P-1009-01A

Bolt, flange connection to exhaust pipe or exhaust manifold

Nm

20

20