Removing Primary Catalytic Converters

→ Wear personal protective gear.

→ Get someone to help if necessary.

→ Let hot components cool down.

→ Wear personal protective gear.

1. Disconnect primary catalytic converters from the main 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
2. Pull off all cable plugs on the lambda sensors. Disconnect cable plugs -1, 2, 3, 4-  and release them from the holders.
   Fig 2: Identifying Cable Plugs On Lambda Sensors

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3. Remove heat protection panel on the exhaust manifold. To do this, remove the sheetmetal holders on the heat protection panel and intake manifold -arrows-  . Pull heat protection panel out of the upper clamps.
   Fig 3: Locating Sheetmetal Holders

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4. Remove primary catalytic converters.

1. 4.1. Remove M8 fastening screw and sheetmetal holder on the transmission next to the starter -2, 3 and 4-  .
   Fig 4: Identifying Catalytic Converter And Holder

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   Information 

   • Mark oxygen sensors as you unscrew them so that the oxygen sensors are not confused. 
2. 4.2. Remove the lambda sensors. This gives more space for removal and prevents damage to the lambda sensors.
3. 4.3. Unscrew all fastening nuts between the primary catalytic converter and exhaust manifold. Spray the six nuts securing the exhaust manifold to the catalytic converter with anti-rust agent and leave it to take effect. Loosen catalytic converters on the exhaust manifolds (six nuts) -arrows-  and lay catalytic converters aside.
   Fig 5: Locating Flange Between Primary Catalytic Converters And Exhaust Manifolds

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 4.4. Lift the two primary catalytic converters up together and remove them from the engine compartment.