18 32 050 Removing and installing/replacing catalytic converter

WARNING: Risk of burning!
Only perform this repair work after the exhaust system has cooled down.

Necessary preliminary work:

Clamp off NEGATIVE BATTERY LEAD .
Remove CONSOLE FOR WINDSCREEN WASHER SYSTEM .
Remove OXYGEN SENSOR .
Remove MONITORING SENSOR .
Remove front UNDERBODY PROTECTION .
Remove EXHAUST SYSTEM .
Remove PROPELLER SHAFT .

Removal:

If fitted: Removing differential pressure sensor for the fuel particulate filter.

Carefully unlock the latch mechanisms (1).

Feed out cover (2) and remove.

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Unfasten plug connection (1) and disconnect.

Detach pressure hose (2).

Release screw (3).

Feed out and remove the differential pressure sensor (4).

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Remove rubber mounts (1) from the catalytic converter.

Check rubber mount. Replaced damaged rubber mounts.

Parts: Rubber mount

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Loosen screws (1).

Feed out heat shield (2) and remove.

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Slacken nut (1).

Feed out heat shield (2) and remove.

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Unscrew nut (3).

Release screw (2).

Remove strut brace (1).

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Loosen the screws along the arrows.

Feed out heat shield (1) and remove.

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Loosen the screws along the arrows.

Feed out heat shield (1) and remove.

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Release screw (1).

Do not remove heat shield (2).

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Loosen the screws along the arrows.

Feed out heat shield (1) and remove.

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Release nuts (1) on the left of the catalytic converter.

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Release clamp (1). The clamp must be replaced every time it is removed.

If necessary, replace clamp.

Parts: Clamp.

Clean sealing surface.

Release catalytic converter (2) from exhaust turbocharger and place to side.

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Feed out catalytic converter (1) upwards and remove.

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Preparation for installation:

Replace gasket (1) on catalytic converter.

Parts: Gasket.

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Installation:

Feed in catalytic converter (1) from the top and place on the front axle.

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Mount catalytic converter (2) on exhaust turbocharger and holder.

Tighten clamp (1).

Tightening torque 18 30 1AZ .

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Tighten down nuts (1).

Tightening torque 18 30 2AZ .

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Feed in and install heat shield (2).

Tighten down screws (1).

Tightening torque 18 30 8AZ .

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Feed in and install heat shield (2).

Tighten nut (1).

Tightening torque 18 30 8AZ .

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Connect rubber mount (1) to catalytic converter.

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Feed in and install heat shield (1).

Tighten screws along arrows.

Tightening torque 18 30 8AZ .

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Tighten screw (1).

Tightening torque 18 30 8AZ .

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Feed in and install heat shield (1).

Tighten screws along arrows.

Tightening torque 18 30 8AZ .

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Feed in and install heat shield (1).

Tighten screws along arrows.

Tightening torque 18 30 8AZ .

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Install strut brace (1).

Tighten nut (3).

Tightening torque 51 61 2AZ .

Tighten screw (2).

Tightening torque 51 61 3AZ .

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If fitted: Install differential pressure sensor for the fuel particulate filter.

Feed in and install the differential pressure sensor (4).

Tighten screw (3).

Tightening torque 13 62 7AZ .

Replace pressure hose (2).

Parts: Pressure hose

Connect the pressure hose (2) with the differential pressure sensor (4).

Connect and lock the connector (1).

The connector (1) must engage audibly.

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Feed in and install the cover (2).

Lock latch mechanisms (1).

The latch mechanisms (1) must audibly engage.

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Required follow-up work:

Install OXYGEN SENSOR.
Install MONITORING SENSOR.
Install EXHAUST SYSTEM .
INSTALL PROPELLER SHAFT.
Install front UNDERBODY PROTECTION .
Install CONSOLE FOR WINDSCREEN WASHER SYSTEM .
Connect NEGATIVE BATTERY LEAD .