Installing Primary Catalytic Converters

Fig 1: Identifying Main And Primary Catalytic Converters

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• 1 - Lambda sensor downstream of catalytic converter
• 2 - Lambda sensor upstream of catalytic converter
• 3 - Primary catalytic converter
• 4 - Lambda sensor downstream of catalytic converter
• 5 - Lambda sensor upstream of catalytic converter
• 6 -Seals
• 7 - Primary catalytic converter
• 8 - Nuts
• 9 - Rubber bracket
• 10 - Cross member
• 11 - Screws
• 12 - Seals
• 13 - Main catalytic converters
• 14 - Nuts

1. Clean all sealing surfaces and replace metal seals. Replace nuts.
2. Install primary catalytic converter. Fit all screws and nuts before finally tightening to the correct tightening torque.
   1. 2.1. Get another person to help you move the two primary catalytic converters together from the engine compartment into installation position. When doing so, make sure that the studs on the exhaust manifolds are inserted into the bores on the primary catalytic converters. Place new fastening nuts on the studs of the exhaust manifolds and an M8 fastening screw on the sheetmetal bracket next to the starter.
   2. 2.2. Loosely tighten fastening nuts on the studs on the exhaust manifolds hand-tight.
      Fig 2: Locating Flange Between Primary Catalytic Converters And Exhaust Manifolds

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   3. 2.3. Fit fastening screws, nuts and the sheetmetal holder next to the starter.
      Fig 3: Identifying Catalytic Converter And Holder

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3. Fit flange between the primary and main catalytic converter using screws.
4. Tighten all threaded connections. Primary catalytic converter to exhaust manifold → Tightening torque: 40 Nm (30 ft lbs.);  sheetmetal bracket to primary catalytic converter → Tightening torque: 23 Nm (17 ft lbs.);  flange connection between main and primary catalytic converter → Tightening torque: 23 Nm (17 ft lbs.  )
5. Fit lambda sensors. → Installing oxygen sensor ahead of catalytic converterInstalling oxygen sensor behind catalytic converter
6. Plug in all cable plugs on the lambda sensors. -1, 2, 3, 4-  Use PIWIS Tester to check correct assignment to lambda sensors if necessary.
   Fig 4: Identifying Cable Plugs On Lambda Sensors

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7. Fit heat protection panel on exhaust manifold. Press heat protection panel into the upper sheetmetal clamps. Then fit sheetmetal holder on heat protection panel and on intake manifold -arrows-  . → Tightening torque: 20 Nm (15 ft lbs.) 
   Fig 5: Locating Sheetmetal Clamps

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