Installing Primary Catalytic Converter On Cylinder Bank 5-8

1. Ensure sealing faces of exhaust system are clean.
2. Replace flange gasket -4-  and slide it over the studs on the exhaust manifold -5-  .
   1. Primary Catalytic Converter
   2. Ceramic Monolith
   3. Exhaust Manifold
   4. Seal
   5. Studs In Exhaust Manifold
      Fig 1: Identifying Ceramic Monolith And Flange Gasket

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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.

3. Carefully move primary catalytic converter into installation position.
4. Fit new fastening nuts between the exhaust manifold and primary catalytic converter, but leave them loose.
5. Make sure that the sheetmetal holder for the primary catalytic converter fits correctly on the exhaust manifold after you tighten the nuts -8-  .
   Fig 2: Identifying Catalytic Converter Holder Related 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. Screw
   8. Holder, Right
   9. Primary Catalytic Converter, Right
   10. Bolts Between Transmission And Engine (Holder)
6. Fit fastening screw on catalytic converter holder and nuts to the specified tightening torque and according to the specified tightening sequence → Flange bolts securing primary catalytic converter to exhaust manifold → Tightening Torque: 23 Nm (17 ft. lb.) → Tightening Torque: 23 Nm (17 ft. lb.)  . For details of tightening torque for transmission screws, see Removing and installing transmission or Removing and mounting transmission.

   1 to 5  - Tightening sequence for nuts

   Fig 3: Identifying Primary Catalytic Converter To Exhaust Manifold Flange Nut Tightening Sequence

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   WARNING: Cables not fitted or removed correctly

   • Risk of burns
   • Risk of short circuit or fire.

   → Check for correct fitting.

   → Replace damaged components.

7. Lay oxygen sensor cable and clip it in. -1- 
   Fig 4: Identifying Catalytic Converter On Naturally Aspirated Engine

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8. Fit heat shield on the cardan joint of the steering column. -arrows- → Tightening Torque: 10 Nm (7.5 ft. lb.) 
   Fig 5: Locating Heat Shield On Steering Gear

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9. Fit coolant pipe on converter bell housing -arrow-  . → Tightening Torque: 9 Nm (6.5 ft. lb.) 
   Fig 6: Locating Coolant Pipes On Converter Bell Housing

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10. Plug in the connector for the oxygen sensor behind the catalytic converter at the water splash panel.

Information 

• To loosen and tighten fastening nuts on flange of turbocharger, several extensions and joints must be used  .
• Good lighting and a mirror make removal and fitting easier at places very difficult to reach  .
  Fig 1: Identifying Catalytic Converter Holder And Related Components (Turbo Engine)

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  1. Positioning Lug On Left Side, Viewed In Direction Of Travel
  2. Positioning Lug On Right Side, Viewed In Direction Of Travel
  3. Turbocharger, Left
  4. Seal
  5. Nut
  6. Primary Catalytic Converter, Left
  7. Screw
  8. Sheetmetal Holder (Support)
  9. Sheetmetal Holder (Support)
  10. Primary Catalytic Converter, Right
  11. Turbocharger, Right
  12. Screw
  13. Mounting Point On Crankcase

1. Replace flange gasket and push over the studs of the turbocharger.
2. Position the primary catalytic converter on the bolts on the turbocharger. To do this, carefully turn and pull the primary catalytic converter. Move the steering if necessary and move the primary catalytic converter into installation position.
   Fig 2: Placing Primary Catalytic Converter On Studs Of Turbocharger

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3. Fit side catalytic converter holders.
4. Position new self-locking nuts at the connection points of the catalytic converter and tighten to the specified tightening torque. → Tightening Torque: 23 Nm (17 ft. lb.) 
5. Tighten side catalytic converter holders to the specified tightening torque → Tightening Torque: 23 Nm (17 ft. lb.)  . For details of transmission flange screws, see → 373519 REMOVING AND INSTALLING TRANSMISSION
6. Fit the heat shield on the steering gear connection. To do this, fit the fastening screws. → Tightening Torque: 10 Nm (7.5 ft. lb.) 
   Fig 3: Locating Fastening Screws Securing Heat Shield To Steering Gear Connection

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   WARNING: Cables not fitted or removed correctly

   • Risk of burns
   • Risk of short circuit or fire.

   → Check for correct fitting.

   → Replace damaged components.

7. Route oxygen sensor cables upwards so that the oxygen sensor cables are not touching the exhaust manifold or the exhaust system and clip them into position -1-  . A useful aid here is a piece of wire with a hook.
   Fig 4: Identifying Catalytic Converter On Turbo Engine

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8. Connect the oxygen sensor connectors for the oxygen sensors at the water splash panel and clip the cables into the holders. → Oxygen sensor connectors (figure shows cylinders 1 to 4) 
   Fig 5: Identifying Oxygen Sensor Connectors

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