Removing Primary Catalytic Converter On Cylinder Bank 1-4

→ Let hot components cool down.

→ Wear personal protective gear.

1. Disconnect the oxygen sensor connector for the oxygen sensor behind the catalytic converter at the water splash panel (follow cable routing) and unclip the cables from the holder.
   Fig 1: Removing Oxygen Sensor Connectors

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2. Expose oxygen sensor cable -1-  and route it down to the primary catalytic converter.
   Fig 2: Identifying Catalytic Converter On Naturally Aspirated Engine

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3. Remove sheetmetal holders for the primary catalytic converter -7, 8, 10-  .
   Fig 3: Identifying Holder For Catalytic Converter Components - Naturally Aspirated Engine

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   • 1 - Exhaust manifold, right
   • 2 - Exhaust manifold, left
   • 3 - Seal
   • 4 - Nut
   • 5 - Primary catalytic converter, left
   • 6 - Holder, left
   • 7 - Bolt
   • 8 - Holder, right
   • 9 - Primary catalytic converter, right
   • 10 - Bolts between transmission and engine (holder)
   NOTE: Studs and nuts not loosened correctly

   • Threaded bolts can break off exhaust manifold

   → Replace damaged exhaust manifold.

   → Clean the studs and nuts on the exhaust manifold before loosening them and spray with anti-rust agent.

   → Loosen nuts carefully. Loosen the nuts by carefully turning them in both directions if they are very stiff.

   → Heat the threaded joint if necessary.

4. Carefully loosen the flange nuts using a change-over ratchet and several extensions. -2-  .
   Fig 4: Identifying Catalytic Converter Loosening Order (Naturally Aspirated Engine)

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   1 bis 5  - Tightening sequence for nuts

   Fig 5: Identifying Flange Bolts Tightening Sequence Primary Catalytic Converter To Exhaust Manifold

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   NOTE: Projecting ceramic catalytic converter

   • Risk of damage to ceramic catalytic converter

   → Ensure that your work area is well illuminated.

   → Carefully guide the projecting ceramic catalytic converter past the studs on the exhaust manifold.

   → Cover and store the ceramic monolith for the primary catalytic converter in a safe place until you are ready to install it.

   → Protect the ceramic monolith from damage while you are working on the primary catalytic converter. If there are deep cracks or large chips, replace the primary catalytic converter. Slight superficial damage will not impair its function.

5. Carefully remove the primary catalytic converter with the help of another worker.
   Fig 6: Identifying Ceramic Monolith And Installation Position

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   • 1 - Primary catalytic converter
   • 2 - Ceramic monolith
   • 3 - Exhaust manifold
   • 4 - Seal
   • 5 - Studs in exhaust manifold
6. Remove sheetmetal seal -4-  . Clean sealing faces.