Removing and installing/replacing the catalytic converter (B36, B38) (Cooper)

Preliminary work needed: 

• Remove OXYGEN SENSOR .
• Remove MONITORING SENSOR .
• Remove front UNDERBODY PROTECTION .
• Remove THRUST FIELD
• Remove EXHAUST SYSTEM .

Removal: 

If fitted: Remove differential pressure sensor for gasoline particulate filter 

Carefully unlock the detents (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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For vehicles with a heat shield: 

Release screws (1) on the exhaust-air duct.

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For vehicles with a heat shield: 

Release screws (1) on left heat shield (3).

Release left heat shield (3) from guide pin (2) and remove.

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For vehicles with a heat shield: 

Release screws (1) on upper heat shield.

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For vehicles with a heat shield: 

Release screw (1) on upper heat shield (2).

Feed out and remove upper heat shield (2).

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

Replace clamp and gasket.

Parts:  clamp and seal.

Clean sealing surface.

Unscrew nuts (2).

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For vehicles without a heat shield: 

Feed out catalytic converter (3) towards bottom and remove.

For vehicles with a heat shield: 

Release catalytic converter (3) from exhaust turbocharger and place to side.

For vehicles with a heat shield: 

Release screws (1) on lower heat shield.

Release screw (2) and remove exhaust-air duct (3).

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For vehicles with a heat shield: 

Release screw (1) on lower heat shield above the exhaust turbocharger.

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For vehicles with a heat shield: 

Release screw (1) on lower left heat shield at the cylinder head.

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For vehicles with a heat shield: 

Place catalytic converter (1) to the side.

Release screws (2) on lower heat shield (3).

Feed out and remove heat shield (3) upwards.

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Release screws (1) and remove upper heat shield (2) at the cylinder head.

Pull out catalytic converter towards the bottom and remove.

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Replace gasket (1) on catalytic converter.

Parts:  Gasket.

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Installation: 

For vehicles without a heat shield: 

Feed in catalytic converter (3) from below and install.

Make sure the seal and clamp between the catalytic converter and exhaust turbocharger are correctly seated.

Tighten clamp (1).

Tightening torque 18 30 1AZ .

Tighten down nuts (2).

Tightening torque 18 30 2AZ .

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For vehicles with a heat shield: 

To facilitate the installation of the heat shields, join all  screws first and tighten them afterwards.

For vehicles with a heat shield: 

Feed in catalytic converter (1) and set aside.

Feed in lower heat shield (2) behind the exhaust turbocharger and secure with screws (2).

Tightening torque 18 30 6AZ .

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For vehicles with a heat shield: 

Secure lower heat shield with screw (1) above the exhaust turbocharger.

Tightening torque 18 30 6AZ .

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For vehicles with a heat shield: 

Secure lower heat shield with screw (1) on the left side of the cylinder head.

Tightening torque 18 30 6AZ .

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For vehicles with a heat shield: 

Join screws (1) on bottom of heat shield and tighten screws.

Tightening torque 18 30 6AZ .

Mount exhaust-air duct (3) and tighten screw (2).

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For vehicles with a heat shield: 

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

Tighten clamp (1).

Tightening torque 18 30 1AZ .

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For vehicles with a heat shield: 

Tighten down nuts (1).

Tightening torque 18 30 6AZ .

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For vehicles with a heat shield: 

Feed in upper heat shield (2) and secure with screw (1).

Tightening torque 18 30 6AZ .

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For vehicles with a heat shield: 

Secure upper heat shield with screws (1).

Tightening torque 18 30 6AZ .

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For vehicles with a heat shield: 

Mount upper heat shield (2) on the cylinder head and tighten screws (1).

Tightening torque 18 30 3AZ .

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Connect rubber mount (1) to catalytic converter.

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If fitted: Install the differential pressure sensor for gasoline 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 differential pressure sensor (4).

Connect connectors (1) and lock.

The connector (1) must engage audibly.

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Feed in and install the cover (2).

Lock detents (1).

The detents (1) must audibly engage.

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Required follow-up work: 

• Install OXYGEN SENSOR .
• Install MONITORING SENSOR .
• Install EXHAUST SYSTEM .
• Install THRUST FIELD .
• Install front UNDERBODY PROTECTION .