Catalytic Converter: Service and Repair

Three-way catalytic converter (TWC), replacing

Special tools:
999 5543 SOCKET NV-22 HO2S 999 5543 Socket NV-22 HO2S

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Removing the three-way catalytic converter (TWC)





Remove:
- the wiring for the front heated oxygen sensor (HO2S) from the clips and clamps. Separate the wiring. Raise the car
- the lower engine cover
- the front SIPS member. Unhook the brake pipe from the clips
- the lower screw in the heat deflector plate on the turbocharger (TC)
- the nuts for the flange between the turbocharger (TC) and the three-way catalytic converter (TWC).

Hint: Use rust solvent or similar.





Remove:
- the rubber mounting for the three-way catalytic converter (TWC)
- the nuts for the flange between the three-way catalytic converter (TWC) and exhaust system
- the wiring for the rear heated oxygen sensor (HO2S) from the clips and clamps. Separate the wiring
- the three-way catalytic converter (TWC).

Transferring components




- Transfer the rear and front heated oxygen sensors (HO2S). Use tool 999 5543 SOCKET NV-22 HO2S 999 5543 Socket NV-22 HO2S.

Caution! Do not mix up the heated oxygen sensors (HO2S).

- Tighten.

Installing the three-way catalytic converter (TWC)

Note! For tightening see Tightening torque Tightening Torque.

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.

Lubricate the studs on the turbocharger (TC). Use paste, P/N: 1161408. Avoid skin contact with the paste.

Install:
- the three-way catalytic converter (TWC). Use new nuts and gaskets. Tighten. See Tightening torque Tightening Torque
- the wiring for the rear heated oxygen sensors (HO2S) using the clips and the clamps. Connect the wiring
- the rubber mounting for the three-way catalytic converter (TWC)
- the lower screw in the heat deflector plate above the turbocharger (TC)
- the SIPS (side impact protection system ) member. Secure the brake pipe to the member
- the lower engine cover.
Lower the car.
Install the wiring for the front heated oxygen sensor (HO2S) using clips and clamps. Connect the wiring.

Final check
Start the engine. Check for exhaust leakage.