P49.20-A097-78
1 | Catalytic converter | 4 | Bracket | G3/1 | Oxygen sensor downstream of catalytic converter | ||
2 | V-band clamp | 5 | Nut | G3/2 | Oxygen sensor upstream of catalytic converter | ||
3 | Metal seal |
Warning | Risk of injury. Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | |
Warning | Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust. | Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area. | |
Caution | Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. | |
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Topical note | Notes on bolted connections with self tapping screws | ||
Topical note | Notes on self-locking nuts and bolts | ||
| Remove | ||
1 | Remove center exhaust system. | ||
2 | Remove oxygen sensor upstream of catalytic converter (G3/2). | ||
3 | Remove lambda sensor downstream of catalytic converter (G3/1). | ||
4 | Remove heat shield of the catalytic converter (1). | ||
5 | Remove V-band clamp (2). | ||
6 | Remove nut (5) from the bracket (4). | ||
7 | Remove catalytic converter (1) with bracket (4) from the engine compartment. | ||
8 | Remove metal seal (3) from the exhaust gas turbocharger. | ||
| Clean | ||
9 | Clean connecting flange on the catalytic converter (1) and then seal openings on the catalytic converter (1) with protective covers. | If the catalytic converter (1) is reused. | |
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Set of protective caps | |||
10 | Clean connecting flange on the exhaust gas turbocharger and then seal openings on the exhaust gas turbocharger with protective covers. | | |
Set of protective caps | |||
| Install | ||
11 | Remove protective covers from the catalytic converter (1) and exhaust gas turbocharger. | ||
12 | Insert new metal seal (3) in the exhaust gas turbocharger. | ||
13 | Lift catalytic converter (1) with bracket (4) into the engine compartment. | ||
14 | Position bracket (4) with catalytic converter (1) and screw in a new nut (5) by approx. 3 revolutions. | ||
15 | Press catalytic converter (1) onto the exhaust gas turbocharger and align. | ||
16 | Align new V-band clamp (2) and align. | The joint (arrow B) of the V-band clamp (2) must be flush with the marking (arrow A). | |
17 | Tighten V-band clamp (2). | After tightening, there must be no gap at the joint (arrow B) of the V-band clamp (2). | |
Clamp at turbocharger and catalytic converter/front exhaust line | |||
18 | Tighten nut (5) on the bracket (4). | Nut for catalytic converter bracket on bracket | |
19 | Install heat shield of the catalytic converter (1). | ||
Bolt, heat shield to engine support | |||
20 | Install lambda sensor downstream of the catalytic converter (G3/1). | ||
21 | Install lambda sensor upstream of the catalytic converter (G3/2). | ||
22 | Install center exhaust system. | ||
| Check | ||
Warning | Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running. | Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. | |
23 | Perform engine test run; check engine for proper operation and check exhaust system for leak tightness. |
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Set of protective caps