Catalytic Converter: Service and Repair

Assemble special tool 00 0 200 with special tool 00 0 201 / 00 0 202 / 00 0 204 / 00 0 208 and install.
Secure special tool 00 0 200 to front suspension eye on engine.

Note: The supports (1) of special tool 00 0 208 must rest on the bolt connection of both side walls.





Tighten the screws (1 and 2).





Raise engine with special tool 00 0 200 approx. 5 mm.

Remove exhaust system.
If necessary, remove front end reinforcement.
Remove right engine support arm with engine mount.

Note: The oxygen sensors are in danger of being damaged when the exhaust manifolds are removed and installed.

Remove oxygen control sensors, refer to Powertrain Management.





Remove cover from fuel injectors.
The preliminary tasks are described in Removing engine cover, refer to Engine, Service and Repair.

Note: Do not mix up oxygen monitor sensors for cylinders 1 to 3 and 4 to 6 at plug connection to wiring harness.

Mark plug connections.
Unclip the cable from the retainer. Disconnect plug. Unclip cable on rear side of engine from cable guide.
Remove oxygen monitor sensors, refer to Powertrain Management.

Note: Rear exhaust manifold with catalytic converter can only be removed after front exhaust manifold with catalytic converter has first been removed.

Remove front exhaust manifold with catalytic converter.
Remove rear exhaust manifold with catalytic converter.

Installation:
Clean sealing faces, replace gaskets.
Coat threads with copper paste.
Replace nuts.
Tightening torque, refer to Specifications, Mechanical.