Catalytic Converter: Service and Repair

Front Exhaust Pipe with Catalytic Converter

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Hot bolt paste => Electronic Replacement Parts Catalog "ETKA"

Removing






- Disconnect the harness connector for the heated oxygen sensor (G39) - arrow - and free up the wiring harness.






- From the top, remove the front exhaust pipe with catalytic converter nuts - arrows - from the turbocharger.

- Remove the noise insulation. Refer to

- Remove nuts accessible from below for the front exhaust pipe with catalytic converter to turbocharger.

- 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 exhaust system suspended mount bolts - arrows -.

- Remove the front tunnel bridge nuts - arrows - from the underbody.







Danger of damaging the flex joint:

• The flex joint must not be bent more than 10°.

• Do not load the flex joint.

• Do not damage the wire mesh at the flex joint.

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

- Remove the front exhaust pipe with catalytic converter.

Installing

• Tightening specifications, refer to => [ Exhaust System Overview ] Removal and Replacement.

• Tunnel bridge to underbody nut: 20 Nm

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

• Replace gaskets and self-locking nuts.

• Lubricate the stud bolts on the exhaust manifold with hot bolt paste. Refer to the Parts Catalog.

• Align the exhaust system free of stress. Refer to => [ Exhaust System, Aligning ] Procedures.

• Check the exhaust system for leaks. Refer to => [ Exhaust System, Checking for Leaks ] Testing and Inspection.