Catalytic converter

 To remove


1.Unplug the connector for the oxygen sensors and carefully lower the cables.
2.Remove the heat shield over the turbocharger.
3.Remove the upper oxygen sensor.
4.Remove the nuts for the catalytic converter connection with the turbocharger.

Important

When removing the nuts of the catalytic converter, it is important to hold the removal tool vertically against the flange. The stud and nut can easily be broken off if they are subjected to a skew loading. Use 82 92 484 Removal tool, door hinge.
5.Raise the car.
6.Remove the front spoiler shield . CV: RemoveChassis reinforcement, front supporting frame, CV
7.Remove the lower turbocharger pressure pipe.
8.Cut the front pipe at the silencer (87mm from end of silencer). Use 83 95 667 Pipe cutter/exhaust system

9.Detach the front pipe from the catalytic converter.
10.Remove the heat shield over the steering gear.
11.Remove the heat shield over the catalytic converter.
12.Remove the lower oxygen sensor.
13.Remove the catalytic converter fixing from the engine block and from the catalytic converter.
14.Remove the catalytic converter.
 To fit


1.Lubricate the turbocharger studs with 30 20 971 Screw-thread paste
2.Lift up the catalytic converter, position its bracket to the studs on the engine block and position the catalytic converter to the turbocharger connection.
3.Insert the catalytic converter bracket bolts into the engine block and new nuts on the studs.
4.Lower the car.
5.Fit the catalytic converter with new nuts so that it rests evenly against the turbo.

Tightening torque 25 Nm (18.5 lbf ft)
6.Raise the car.
7.Tighten the catalytic converter nuts and bolts a last time.

Tightening torque 25 Nm (18.5 lbf ft)
8.Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the lower oxygen sensor.

Tightening torque 40 Nm (30 lbf ft).

Important

Make sure that the oxygen sensor cables are not twined or damaged.
9.Lift up the oxygen sensor cables.

Important

Make sure that no cables are pinched or chafed.


10.Fit the heat shield over the catalytic converter.
11.Fit the heat shield over the steering gear.
12.Clean the joint at the catalytic converter and the pipe connections to the front silencer, fit the joint clamps.
13.Mount the joint clamp and fit the front pipe with a new gasket, new nuts and rubber mountings. Lubricate the studs with 30 20 971 Screw-thread paste .
14.Move over the joint clamp so that the pipe ends are in the middle of the clamp.
15.Tighten the joint with the catalytic converter.

Tightening torque 25 Nm (18.5 lbf ft)
16.Tighten the joint clamp nuts.

Tightening torque 40 Nm (30 lbf ft).
17.Fit the turbocharger delivery pipe. CV: Fit Chassis reinforcement, front supporting frame, CV
18.Lower the car.
19.Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the upper oxygen sensor.

Tightening torque 40 Nm (30 lbf ft).
20.Plug in and secure the oxygen sensor connectors.
21.Fit the turbocharger heat shield.