Removing and installing/replacing catalytic converter (Cooper S)

WARNING: Risk of burning!
This repair may only be carried out on an exhaust system which has cooled down.

Preliminary work needed:

Disconnect BATTERY GROUND LEAD .
Remove CONSOLE for windshield washer system.
Remove OXYGEN SENSOR .
Remove MONITORING SENSOR .
Remove front UNDERBODY PROTECTION
Remove EXHAUST SYSTEM .
For all-wheel vehicles:
Remove PROP SHAFT .

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

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

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

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Release screws (1) on upper heat shield.

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

Feed out and remove upper heat shield (2).

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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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Release screws (1) on lower heat shield.

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

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

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

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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.

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Unscrew nut (3).

Release screw (2).

Remove strut brace (1).

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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:

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

Feed in lower heat shield (1) and place on the front axle.

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

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Place catalytic converter (1) to the side.

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

NOTE: Join all screws of the heat shield first and tighten them afterwards.
Tightening torque 18 30 8AZ .

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

NOTE: Join all screws of the heat shield first and tighten them afterwards.
Tightening torque 18 30 8AZ .

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

NOTE: Join all screws of the heat shield first and tighten them afterwards.
Tightening torque 18 30 8AZ .

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

Tightening torque 18 30 8AZ .

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

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

NOTE: Join all screws of the heat shield first and tighten them afterwards.
Tightening torque 18 30 8AZ .

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Secure upper heat shield with screws (1).

NOTE: Join all screws of the heat shield first and tighten them afterwards.
Tightening torque 18 30 8AZ .

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Feed in left heat shield (3) and secure at the guide pin (2).

Join and tighten screws (1).

Tightening torque 18 30 8AZ .

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Tighten screws (1) on exhaust-air duct.

Tightening torque 18 30 8AZ .

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

Tightening torque 18 30 7AZ .

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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 CONSOLE for windshield washer system
For all-wheel vehicles:
Install PROP SHAFT .
Install EXHAUST SYSTEM .
Install front UNDERBODY PROTECTION
Connect BATTERY GROUND LEAD .