Front, catalytic converter, US/CA

 To remove


1.Unplug the connectors for the oxygen sensors (A) and carefully take down the cables.
2.Remove the heat shield (B) over the turbocharger.
3.Remove the upper oxygen sensor (A).
4.Remove the nuts (B) for the catalytic converter connection to 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 .

Remove Chassis reinforcement, front subframe, CV.
7.Remove the lower turbocharger pressure pipe (A).
8.Remove the nuts to the rear catalytic converter (A).
9.Remove the exhaust pipe's rubber mountings (B). Lift down the exhaust pipe.
10.Remove the heat shield over the catalytic converter (A).
11.Remove the lower oxygen sensor (B).
12.Remove the catalytic converter (C) fixing from the engine block and from the catalytic converter.
13.Remove the catalytic converter.
 To fit


1.Lubricate the turbocharger studs with 30 20 971 Screw-thread paste.
2.Lift up the catalytic converter, align its bracket to the studs on the engine block and align the catalytic converter to the turbocharger connection.
3.Insert the catalytic converter bracket bolts (C) into the engine block and new nuts on the studs.
4.Lower the car.
5.Fit the catalytic converter (B) 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 (B).

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 (A) over the catalytic converter.
11.Fit the rear catalytic converter to the front catalytic converter.
12.Hang the exhaust pipe up with the rubber mountings (B).

13.Tighten the connection between the front and rear catalytic converters (A).

Tightening torque 25 Nm (18.5 lbf ft)
14.Fit the turbo delivery pipe (A). Fit the Spoiler shield, front.

CV: Fit the Chassis reinforcement, front subframe, CV.
15.Lower the car.
16.Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the upper oxygen sensor (A).

Tightening torque 40 Nm (30 lbf ft).
17.Plug in and secure the oxygen sensor connectors (A).
18.Fit the turbocharger heat shield (B).