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Front catalytic converter

Front catalytic converter

To remove

Warning

The cooling system is under pressure. Hot coolant and steam can escape.

- Open the cap slowly to release the pressure.

- Carelessness can cause eye and burn injuries



1. Take the cap off the expansion tank to release any pressure.


2. Raise the car.

3. Remove the lower engine cover.


4. Undo the right-hand side of the front spoiler shield and fold it down.

5. Place a suitable receptacle under the radiator. Connect a hose to the radiator and drain the coolant. Close the cock and refit the spoiler shield.

6. Undo and remove the front exhaust pipe.


7. Remove the heat shield lower nuts and bolts.


8. Lower the car.

9. Remove the upper engine cover.

10. Remove the screw holding the dipstick tube.


11. Remove the turbo intake hose and detach the crankcase ventilation hose.

12. Remove the turbocharger inlet pipe and plug the turbo.

13. Remove the turbo delivery pipe and hoses. Plug the pipe and hoses.


14. Remove the delivery hose from the throttle body and delivery pipe.


15. Remove the upper coolant hose from the thermostat housing and bend it aside.


16. Remove the radiator pipe to the reservoir from the engine, two mountings, and the hose from the manifold.

17. Remove the coolant hoses form the coolant pipe on the left-hand side of the engine.

18. Remove the lower coolant hose from the coolant pipe.

19. Undo the front bolts on the upper timing cover. Bend out the cover slightly and insert a wedge.


20. Remove the coolant pipe.


21. Undo the radiator connector and remove the heat shield.

22. Raise the car.

23. Remove the temperature sensor from the catalytic converter.


24. Remove the lower retaining bolts from the catalytic converter. Undo and bend down the mounting.

25. Loosent the nut on the clamp. Hold the clamp open with circlip pliers, for example, and lift down the catalytic converter.


To fit


1. Clean the sealing surfaces.


2. Lift up the catalytic converter and fit it with a new gasket. Hold open the clamp with circlip pliers and turn it until the nut points down. Tighten the clamp.

Tightening torque 20 Nm (15 Nm)

3. Bend back the mounting. Fit the lower retaining bolts for the catalytic converter.

4. Fit the temperature sensor to the catalytic converter.

5. Lower the car.

6. Fit the heat shield and the radiator fan connector.


7. Fit the coolant pipe with a new gasket.

8. Remove the wedge. Bend back the cover and fit the front bolts on the timing cover.


9. Fit the lower coolant hose on the coolant pipe.


10. Fit the coolant hoses to the coolant pipe on the left-hand side of the engine.

11. Fit the coolant pipe to the reservoir on the engine, two mountings and the hose from the manifold.

12. Fit the upper coolant hose to the thermostat housing.

13. Fit the delivery hose to the throttle body and delivery pipe.

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.



14. Remove the plugs and fit the turbocharger delivery pipe and hoses.


15. Remove the plug and fit the turbocharger intake pipe.


16. Fit the crankcase ventilation hose and the turbocharger intake hose.

17. Fit the screw holding the dipstick tube.

18. Fit the upper engine cover.

19. Raise the car.

20. Fit the heat shield lower nut and bolt.


21. Fit the front exhaust pipe with new gaskets.


22. Fit the lower engine cover.


23. Lower the car.

24. Carry out Filling and bleeding the cooling system

25. If a new catalytic converter is fitted : Connect the diagnostic tool to reset adaptation values. Select Menu - Engine - Engine management system - Adjustment - Pre Catalyst Replaced.

26. Connect an exhaust hose and start the engine. Check the exhaust system for leaks.