Catalytic Converter: Service and Repair

Front Exhaust Pipe with Catalytic Converters and Front Muffler

Removing






- Remove the heated oxygen sensor (G39).

- Remove the engine cover - arrows -.






- Remove the bolts - arrows - and air guide.

- Remove the coolant hose by loosening the hose clamp - 1 -.






- Disconnect the connector - 2 - from the Mass Airflow (MAF) Sensor (G70).

- Detach upper section of air filter housing - arrow - and remove air filter insert.

- Remove the bolts - arrows - and the lower section of the air filter housing.






- Remove bolt - arrow -.






- Loosen the hose clamp - 1 - and lay the air guide pipe aside with the hose - 2 - connected.

• Ignore - 3 -.

- Remove the bolts - arrows - and nuts - 1 - and then remove the heat shield.






- Remove the nuts - arrows - on the front exhaust pipe/turbocharger connection from the top.






• The illustration shows the installation position from below.

- Mark position of flexible disc to bevel box flange for reinstallation.

- Remove driveshaft flexible disc from bevel box - arrows - while counter holding on triangle flange with lever.






The shaft seal - arrow - in the driveshaft flange could be damaged.

• Press driveshaft horizontally as far back and to right side of vehicle as possible.








- Remove bolts - 1 - and - 2 - under the vehicle floor.






- Remove the cover from the oxygen sensor electrical connector bracket.

- Remove the bolt - 3 - and free up the electrical wire to the oxygen sensor.

- Remove the electrical connector - arrow - from the oxygen sensor after three way catalytic converter (G130) from the bracket and disconnect it.






- Remove the bolts - arrows -, exhaust system bracket and tunnel brace.






Risk of damaging decoupling elements.

• Do not bend decoupling element in front exhaust pipe more than 10°.

- Disconnect the exhaust system at the clamping sleeve - arrows -.






- Remove the front exhaust pipe with the catalytic converter and front muffler.

Installing

• For the correct tightening specifications, refer to => [ Muffler Overview ] Muffler Overview.

Installation is performed in reverse order of removal, noting the following.

• Replace seals and self-locking nuts.

• The hose supports, air guide pipes and hoses must be free of oil and grease before installing.

• Secure all hose connections with hose clamps appropriate for the model. Refer to the electronic parts catalog ETKA.

- Install exhaust system free of stress. Refer to => [ Exhaust System, Installing ] Removal and Replacement.