Catalytic Converter: Service and Repair

Front Exhaust Pipe with Catalytic Converter

Special tools, testers and auxiliary items required

• Torque Wrench (5-50 Nm) (V.A.G 1331)

Removing






- Disconnect the heated oxygen sensor connector - arrow - and free up the wiring harness.






- From the top, remove the front exhaust pipe to exhaust manifold/turbocharger nuts - arrows -.

- Remove the noise insulation..

- Remove the front exhaust pipe to exhaust manifold/turbocharger nuts accessible from below.

- Remove the nuts - arrows - and slightly pull the underbody cover downward.






Engine Code CBFA






- Unclip the wires - arrows -, remove the bracket - 2 - and disconnect the electrical connectors - 1 and 3 -.

Engine Code CCTA






- Disconnect the connector - arrow - on the underbody.

- Remove the electrical connector out of the bracket and free up the electrical wire to the oxygen sensor.

Continuation for All






- Remove exhaust system suspended mount bolts - arrows - from the subframe.

- Remove the front cross member nuts - arrows - and cross member.






Danger of causing damage to the coupling element:

• Do not bend the coupling element more than 10°.

• Do not stretch the coupling element.

• Do not damage the wire mesh on the coupling element.

- Loosen the clamping sleeve - 1 - and push it rearward.

- Remove the front exhaust pipe with catalytic converter.

Installing

• Tightening specifications, refer to one of the following:

• Engine code, CCTA, refer to => [ Exhaust System Overview ] Removal and Replacement.

• Engine code CBFA => [ Exhaust System Overview ] Removal and Replacement.

• Cross member to underbody: 20 Nm

Install in the reverse order of removal. Note the following:

• Replace gaskets and self-locking nuts.

• Coat the stud bolts on the exhaust manifold with hot bolt paste, for the hot bolt paste refer to the Parts Catalog.

• Align the exhaust system free of stress. Refer to => [ Exhaust System, Aligning Free of Tension ] Exhaust System, Aligning Free of Tension.

• Check the exhaust system for leaks. Refer to => [ Exhaust System, Checking for Leaks ] Testing and Inspection.