Catalytic Converter: Service and Repair

Exhaust system components, removing and installing

Special tools and equipment






- 3337 ring spanner set






- VAG1332 torque wrench (40 to 200 Nm)

Exhaust manifold, front exhaust pipe and Three Way Catalytic Converter (TWC) with attachments

Notes:

- Components marked with * are checked via On Board Diagnostic (OBD)

- After exhaust system repairs, make sure exhaust system is not under stress and that it has sufficient clearance from the bodywork. If necessary, loosen double clamps and clamp and align exhaust pipe so that sufficient clearance is maintained to the bodywork and support rings carry uniform loads.
- Always replace self locking nuts.
- Align exhaust system lengthwise so that dimension -a- is maintained.






1. Heat shield
2. Bolt: Tighten to 10 Nm
3. Nut -M8- Tighten to 25 Nm, M10. 40 Nm
4. Exhaust manifold
- 2 piece
- Always replace Exhaust manifold
5. Heat shield
- for catalytic converter
6. Connector
- Black, 6-pin
- secured to subframe
7. Nut: Tighten to 10 Nm
8. Front exhaust pipe
- for removing and installing: Remove Vehicle Speed Sensor (VSS) at transmission
9. Heated Oxygen Sensor (HO2S) G39-*, 50 Nm
- Only use "G 052 112 A3" to grease thread; do not let "G 052 112 A3" get onto slit of oxygen sensor
- use 3337 ring spanner to remove and install
10. Gasket
- Always replace Exhaust manifold Gasket
11. Rubber damper
- for front exhaust pipe, item 8
- secured to subframe
12. Support
- for rubber damper
- secured to subframe
13. Connector
- Brown, 4-pin
14. Heated Oxygen Sensor (HO2S) 2 -G108*, 50 Nm
- Installation location: in catalytic converter
- Only use "G 052 112 A3" to grease thread; do not let "G 052 112A3" get onto slit of oxygen sensor
- use 3337 ring spanner to remove and install
15. to front muffler
16. Catalytic converter
17. Heat shield
18. Dimension -a- = at least 10 mm
19. Support ring
- Replace if damaged
- Note installed position