Catalytic Converter, Intake And Exhaust System - Removal, Replacement And Installation

• Catalytic Converters And Emissions Equipment (B5204T5; B5254T4; B5234T3; B5244T3; B5244T5; B5254T2; B5254T4, TF-80SC AWD; 2003-2009)
  • Heated oxygen sensor (HO2S), replacing
    • Notes
    • Removal and Installation
      • Notes
      • Removing the front heated oxygen sensor (HO2S)
      • Installing the front heated oxygen sensor (HO2S)
      • Removing the rear heated oxygen sensor (HO2S)
      • Installing the rear probe
      • Erase Diagnostic Trouble Codes (DTCs)
      • Reset trim
  • Three-way catalytic converter (TWC), replacing
    • Notes
    • Removing the three-way catalytic converter (TWC)
    • Transferring components
    • Installing the three-way catalytic converter (TWC)
    • Final check
• Catalytic Converters And Emissions Equipment (B5234T3; B5244T3; 2001-2002)
  • Heated oxygen sensors (HO2S), replacing
    • Notes
    • Heated oxygen sensors (HO2S), removing
    • Installing heated oxygen sensors (HO2S)
    • Erase Diagnostic Trouble Codes (DTCs)
    • Reset trim
  • Replacing the three-way catalytic converter (TWC)
    • Notes
    • Removing the three-way catalytic converter (TWC)
      • Removing the three-way catalytic converter (TWC)
    • Installing the three-way catalytic converter (TWC)
      • Transferring components
      • Installing the three-way catalytic converter (TWC)
      • Check
• Catalytic Converters And Emissions Equipment (B5244S; B5244S6; 2001-2006)
  • Heated oxygen sensor (HO2S), replacing
    • Heated oxygen sensors (HO2S), removing
    • Installing heated oxygen sensors (HO2S)
    • Erase Diagnostic Trouble Codes (DTCs)
    • Reset trim
  • Replacing the three-way catalytic converter (TWC)
• Catalytic Converters And Emissions Equipment (B5244S; 2003-2006)
  • Heated oxygen sensor (HO2S), replacing
  • Three-way catalytic converter (TWC), replacing
    • Notes
    • Removing the three-way catalytic converter (TWC)
      • Notes
      • Removing the three-way catalytic converter (TWC)
    • Installing the three-way catalytic converter (TWC)
      • Notes
      • Transferring components
      • Installing the three-way catalytic converter (TWC)
      • Check
• Inlet And Exhaust System (B5204T5, Aw55-50/51SN; B5204T5, M56; B5254T2, M56; B5254T2, Aw55-50/51SN; 2005-2009)
  • Intake pipe/gasket, replacement
    • Removal
      • Notes
      • Removing the intake manifold and gasket
      • Transferring components when replacing the intake manifold
    • Installation
      • Installing the intake manifold and gasket
      • Finishing
      • Final check
  • Replacing the exhaust manifold and gasket
  • Throttle body (electronic throttle module (ETM)), replacing
    • Notes
    • Removal
      • Preparation
      • Removing the electronic throttle module (ETM)
    • Installation
      • Notes
      • Replacing the electronic throttle module (ETM)
      • Installing components
      • Finishing
• Inlet And Exhaust System (B5254T2, Aw50/51 AWD; 2005-2009)
  • Exhaust manifold / gasket, replacing
  • Intake pipe/gasket, replacement
  • Throttle body (electronic throttle module (ETM)), replacing
• Intake And Exhaust Manifold (B5244S; 2003-2006)
  • Exhaust manifold / gasket, replacing
    • Notes
    • Removing manifold / gasket
    • Installing the manifold / gasket
  • Intake pipe/gasket, replacement
    • Notes
    • Removal
      • Removing the intake manifold and gasket
      • Transferring components
    • Installation
      • Notes
      • Installing the intake manifold and gasket
      • Finishing
      • Final check
  • Throttle body (electronic throttle module (ETM)), replacing
    • Removing the throttle body (TB)
    • Installing the throttle body (TB)
• Intake And Exhaust Manifold (B5244S6; 2003-2006)
  • Exhaust manifold / gasket, replacing
    • Exhaust manifold / gasket, replacing
      • Notes
      • Preparation
      • Removing the exhaust manifold and three-way catalytic converter (TWC)
      • Installing the exhaust manifold and three-way catalytic converter (TWC)
      • Finishing
    • Replacing the right half shaft
      • Preparatory removal
      • Installation
  • Intake manifold/gasket, replacing
    • Notes
    • Removal
      • Removing the intake manifold and gasket
      • Transferring components
    • Installation
      • Notes
      • Installing the intake manifold and gasket
      • Finishing
      • Final check
  • Throttle body (electronic throttle module (ETM)), replacing
• Intake And Exhaust Manifold (B5244T3, Aw50/51 AWD; 2003)
  • Exhaust manifold / gasket, replacing
  • Intake pipe/gasket, replacement
  • Throttle body (electronic throttle module), replacing
    • Removal and Installation
      • Notes
      • Removing the throttle body (TB)
      • Installing the throttle body (TB)
• Intake And Exhaust Manifold (B5254T2, Aw50/51 AWD; 2003-2004)
  • Exhaust manifold / gasket, replacing
  • Intake pipe/gasket, replacement
  • Throttle body (electronic throttle module), replacing
• Intake And Exhaust Manifold (B5254T4; 2004)
  • Exhaust manifold / gasket, replacing
  • Intake pipe/gasket, replacement
    • Removal
      • Notes
      • Removing the intake manifold and gasket
      • Transferring components when replacing the intake manifold
    • Installation
      • Installing the intake manifold and gasket
      • Finishing
      • Final check
  • Throttle body (electronic throttle module), replacing
• Intake And Exhaust Manifold (B5254T4; 2005-2007)
  • Exhaust manifold / gasket, replacing
  • Intake pipe/gasket, replacement
  • Throttle body (electronic throttle module (ETM)), replacing
    • Notes
    • Removal
      • Removing the air cleaner (ACL)
      • Removing the electronic throttle module (ETM)
    • Installation
      • Notes
      • Replacing the electronic throttle module (ETM)
      • Installing the air cleaner (ACL)
      • Finishing
• Intake And Exhaust Manifold (B5254T4, TF-80SC AWD; 2006-2007)
  • Exhaust manifold / gasket, replacing
  • Intake pipe/gasket, replacement
  • Throttle body (electronic throttle module), replacing
• Intake And Exhaust Manifolds (B5204T5, Aw55-50/51SN; B5204T5, M56; 2004)
  • Intake pipe/gasket, replacement
    • Notes
    • Replacing intake pipe and gasket
      • Removing the intake manifold and gasket
      • Transferring components when replacing the intake manifold
      • Installing the intake manifold and gasket
      • Finishing
      • Final check
  • Replacing the exhaust manifold and gasket
  • Replacing the throttle body (TB)
    • Removing the throttle body (TB)
    • Installing the throttle body (TB)
• Intake And Exhaust Manifolds (B5234T3; B5244T3; 2001)
  • Intake pipe/gasket, replacement
  • Replacing the exhaust manifold and gasket
  • Throttle body (electronic throttle module (ETM)), replacing
    • Removing
      • Disconnect the negative battery lead
      • Removing the charge air pipe and charge air hose
      • Removing the fan shroud
      • Removing the throttle body
      • Remove the cylinder block screws
      • Removing the throttle body screws
    • Installing
      • Notes
      • Installing the throttle body
      • Install the cylinder block screws
      • Remove the splashguard
      • Install the charge air hose
      • Installing the fan shroud
      • Installing the charge air pipe and charge air hose
      • Install the dipstick tube and negative battery lead
      • Ordering and downloading software
      • Finishing
• Intake And Exhaust Manifolds (B5234T3; B5244T3; 2002)
  • Intake pipe/gasket, replacement
  • Replacing the exhaust manifold and gasket
  • Replacing the throttle body (TB)
• Intake And Exhaust Manifolds (B5234T3, Aw55-50/51SN; B5234T3, M56; B5254T2, Aw55-50/51SN; B5254T2, M56; 2003-2004)
  • Intake pipe/gasket, replacement
  • Replacing the exhaust manifold and gasket
  • Replacing the throttle body (TB)
• Intake And Exhaust Manifolds (B5244T3, Aw55-50/51SN; B5244T3, M56; 2003)
  • Intake pipe/gasket, replacement
  • Replacing the exhaust manifold and gasket
  • Replacing the throttle body (TB)
• Intake System (B5244S; 2001-2002)
  • Exhaust manifold / gasket, replacing
  • Intake pipe/gasket, replacement
    • Notes
    • Replacing the intake manifold and gasket
      • Removing the intake manifold and gasket
      • Transferring components when replacing the intake manifold
      • Installing the intake manifold and gasket
      • Finishing
      • Final check
  • Throttle body (electronic throttle module, ETM), replacing
    • Replacing the electronic throttle module (ETM)
    • Installing the throttle body (electronic throttle module (ETM))
    • Ordering software
    • Finishing
• Muffler And Exhaust Pipe (2001-2005)
  • Exhaust system, replacing
    • Notes
    • Removing the exhaust system
    • Installing the exhaust system
  • Muffler, rear, replace
    • Removing the rear muffler
    • Installing the rear muffler
    • Check
• Turbocharger - Gaskets, Oil Return Pipes, Replacing (2001-2009)
  • Gaskets, turbocharger oil return pipes, replacing
    • Raise the car.
      • Raise the car.
      • Remove the splash guard
    • Oil pipe removal
      • Oil pipe removal
      • Coolant pipe removal
      • Disassemble
    • Coolant pipe reattachment
      • Coolant pipe reattachment
      • Reinstall the splash guard
• Turbocharger (B5204T5; 2005-2007)
  • Replacing the turbocharger (TC) control valve
    • Removing the turbocharger (TC) control valve
    • Installing the turbocharger (TC) control valve
  • Turbocharger (TC), replacing
    • Notes
    • Preparatory work
      • Removing components
      • Draining coolant
    • Removal
      • Removing components from the turbocharger (TC)
      • Disconnecting the front suspension components
      • Disconnecting the front suspension components, continued
      • Removing the drive shaft from the wheel hub
      • Removing the drive shaft
      • Removing the propeller shaft
      • Removing bevel gear
      • Removing the three-way catalytic converter (TWC)
      • Removing the support bracket
      • Removing the turbocharger (TC) and exhaust manifold
    • Installation
      • Notes
      • Assembling the turbocharger (TC)
      • Installing the turbocharger and exhaust manifold
      • Installing components on the turbocharger (TC)
      • Installing the bracket
      • Installing the bevel gear
      • Installing the propeller shaft
      • Installing the three-way catalytic converter (TWC)
      • Installing the drive shaft and bearing cap on the pilot bearing for the shaft
      • Installing the drive shaft
      • Installing the components engine compartment
    • Finishing
      • Routing the joint
      • Installing the lower engine cover and right-hand front wheel
      • Check
• Turbocharger (B5204T5, Aw55-50/51SN; B5204T5, M56; B5234T3, Aw55-50/51SN; B5234T3, M56; B5244T3, Aw55-50/51SN; B5244T3, M56; B5254T2, Aw55-50/51SN; B5254T2, M56; 2001-2004)
  • Turbocharger (TC)
    • Notes
    • Removing the turbocharger (TC)
    • Replacing the manifold and gasket
    • Checking the pressure regulator
    • Installing the turbocharger (TC)
• Turbocharger (B5244T3, Aw50/51 AWD; B5254T2, Aw50/51 AWD; B5254T4, Aw50/51 AWD; B5254T4, M66 AWD; 2002-2007)
  • Turbocharger, replacing
    • Notes
    • Preparatory work
      • Removing components
      • Draining coolant
      • Removal of catalytic converter
    • Removal
      • Disconnecting the front suspension components
      • Removing the drive shaft
      • Removing the propeller shaft
      • Removing bevel gear
      • Removing components
      • Removing the turbocharger (TC)
      • Removing manifold and gasket
    • Installation
      • Notes
      • Installing the manifold/gasket
      • Fitting of turbo unit
      • Installing the bevel gear
      • Installing the propeller shaft
      • Fitting of catalytic converter
      • Installing the drive shaft and bearing cap on the pilot bearing for the shaft
      • Installing the drive shaft
      • Installing the wheels
      • Installing components
    • Finishing
      • Checks
• Turbocharger (B5244T5; 2005-2009)
  • Replacing the turbocharger (TC) control valve
  • Turbocharger (TC), replacing
    • Notes
    • Preparatory work
      • Removing components
      • Draining coolant
      • Removing the three-way catalytic converter (TWC)
    • Removal
      • Disconnecting the front suspension components
      • Removing the drive shaft from the wheel hub
      • Removing the drive shaft
      • Removing the propeller shaft
      • Removing bevel gear
      • Removing the support bracket
      • Removing components
      • Removing the turbocharger and exhaust manifold
      • Installing the turbocharger/exhaust manifold
    • Installation
      • Notes
      • Installing the gasket
      • Installing the turbocharger (TC) and exhaust manifold
      • Installing components
      • Installing the bracket
      • Installing the bevel gear
      • Installing the propeller shaft
      • Installing the three-way catalytic converter (TWC)
      • Installing the drive shaft and bearing cap on the pilot bearing for the shaft
      • Installing the drive shaft
      • Fitting the wheel
    • Finishing
      • Checks
• Turbocharger (B5254T2; 2005-2009)
  • Replacing the turbocharger (TC) control valve
  • Turbocharger (TC), replacing
• Turbocharger (B5254T4, TF-80SC AWD; 2006-2007)
  • Replacing the turbocharger (TC) control valve
  • Turbocharger, replacing