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Front catalytic converter, aut. B284

Front catalytic converter, aut. B284

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


To remove

Important

Always use wing covers when working in the engine bay.



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


2. Remove the upper engine cover and battery cover.

3. Disconnect the negative cable from the battery.

4. Raise the car.

5. Undo the right-hand side of the spoiler shield.

6. 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.


Important

Be careful with the flexible part. It must not be bent by more than 5°.


7. Remove the front bolts of the rear catalytic converter. Move the catalytic converter aside and secure it with 83 95 212 Strap .

8. Remove the mounting from the front catalytic converter and oil sump using 32 025 061 Crow foot spanner .


9. Lower the car.

10. Remove the battery.

11. Remove the main fuse box in front of the battery tray and cable duct. Remove the fuse holder from the battery tray.



Important

Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to Connectors, handling and inspection .


12. Unplug the bonnet switch connector and remove the battery tray.

13. Detach the hoses from the expansion tank.


14. Move up the tank, unplug the level sensor connector and remove the quick coupling of the coolant hose.

15. Remove the heat shields from the turbocharger and catalytic converter.


16. Remove the brake servo heat shield.


17. Remove the turbocharger coolant return pipe.


18. Remove the cable duct from the gearbox.


19. Lift off the cable connection from the shift arm on the gearbox.


20. Remove the shift cable from the cable holder on the gearbox. Lift up and secure the shift cable in the coolant reservoir mounting on the bulkhead.

21. Remove the cable holder from the gearbox.


22. Unplug the connector of the rear oxygen sensor.


23. Remove the rear oxygen sensor by lifting the heat shield and using 83 96 350 Removal socket, oxygen sensor .

24. Unplug the connector of the upper oxygen sensor and move up the cable.


25. Carefully raise the heat shield slightly. Use 83 96 350 Removal socket, oxygen sensor when the oxygen sensor is removed.

26. Position a jack under the gearbox.

27. Mark the position of the bolts and undo the left engine mounting. Carefully release the engine down onto the subframe.


28. Remove the nuts. Lubricate the studs and nuts with rust removal oil.


29. Remove the catalytic converter from the bracket and move it aside.

30. Remove the bracket bolts and nut.


31. Carefully coax up the catalytic converter as illustrated.





To fit


1. Position the catalytic converter.

2. Fit the bracket to the engine.

Tightening torque 42 Nm (31 lbf ft)


3. Insert the lower bolt in the bracket.

Important

When fitting the front catalytic converter to the turbocharger, tighten the nuts in a crosswise pattern to avoid tightening the flange crooked.



4. Fit the flange using new nuts. Coat the studs with 90 513 210 Universal paste . Tighten the nuts alternatingly.

Tighten the bolt in the bracket.

Tightening torque, nuts: 25 Nm (18 lbf ft)

Tightening torque, bolt: 19 Nm (14 lbf ft)

5. Raise the engine with the jack and mount the left engine pad following the mark.

Tightening torque 80 Nm (59 lbf ft).


6. Remove the jack.

7. Fit the upper oxygen sensor.

Tightening torque 45 Nm (33 lbf ft).


8. Secure the cable and plug in the connector.

9. Fit the lower oxygen sensor.

Tightening torque 45 Nm (33 lbf ft).


10. Plug in the connector.

11. Fit the cable holder to the gearbox.


12. Fit the shift cable to the cable holder and connect it to the shift arm.


13. Fit the cable duct.


14. Fit the turbocharger coolant return pipe. Fit the banjo screw using new gaskets.

Tightening torque 30 Nm (22 lbf ft)


15. LHD: Fit the brake servo heat shield.

Tightening torque 8 Nm (6 lbf ft)


16. Fit the heat shields to the turbocharger and catalytic converter.


17. Plug in the level sensor connector and fit the coolant hose quick coupling. Press the coolant reservoir into the mounting on the bulkhead.


18. Attach the hoses to the expansion tank.

19. Fit the battery tray and plug in the bonnet switch connector.


20. Fit the main fuse box in front of the battery tray and the cable duct on the side.


21. Fit the battery.

22. Raise the car.

23. Fit the lower mounting.

Tightening torque to oil sump: 23 Nm (17 lbf ft)

Tightening torque to exhaust pipe flange: 40 Nm (30 lbf ft)


24. Fit the rear catalytic converter.

25. Lower the car.

26. Fit the battery negative cable.

27. Carry out Cooling system pressure testing and Bleeding and charging the cooling system, B284 .

28. Fit the upper engine cover and battery cover.

29. Carry out Procedures after reconnecting the battery .