Front Catalytic Converter, 4WD
Front Catalytic Converter, B284, 4WD
WARNING:
The cooling system is under pressure. Hot coolant and steam can escape.
^ Open the cap slowly to release the pressure.
^ Carelessness can cause eye and burn injuries
To remove
IMPORTANT: Always use wing covers when working in the engine bay.
1. Take the cap off the expansion tank to release any pressure.
2. Remove the upper engine cover and battery cover.
3. Disconnect the negative cable from the battery.
4. Raise the car.
5. Undo the right-hand side of the spoiler shield.
6. Place a suitable receptacle under the radiator. Connect a hose to the radiator and drain the coolant. Close the cock and refit the spoiler shield.
IMPORTANT: Be careful with the flexible part. It must not be bent by more than 5 degrees .
7. Remove Rear catalytic converter, B284, 4WD.
8. RHD: Remove Alternator, B284, 4WD, (RHD).
9. LHD: Remove the right wing liner (A).
10. LHD: Relieve the load on the belt tensioner and unhook the belt. Use a 1/2 inch puller (B).
11. LHD: Disconnect the electrical connections (A) of the alternator
12. LHD: Remove the alternator retaining bolts (B). Move the engine to the left slightly if necessary. Move the alternator rearward.
13. Unplug the oil level sensor connector (A) and remove the cable fixing (B).
14. Remove the bracket (C) from the front catalytic converter and oil sump.
15. Lower the car.
16. Remove Battery cover, bottom, B284.
17. Detach the hoses (A) from the expansion tank.
18. Move up the tank, unplug the level sensor connector (B) and remove the quick coupling of the coolant hose (C).
19. Remove the heat shield from the turbocharger (A) and catalytic converter (B).
20. LHD: Remove the brake servo heat shield (C).
21. Remove the turbocharger coolant return pipe (D).
22. Remove the cable duct from the gearbox (E).
Manual Transmission:
Automatic Transmission:
23. Manual Transmission: Lift the cable connections (A) off of the gearbox shifter arm.
24. Manual Transmission: Detach the gear cables (B) from the gearbox cable holder.
25. Automatic Transmission: Lift the cable connection (A) off of the gearbox shifter arm.
26. Automatic Transmission: Detach the gear cable (B) from the gearbox cable holder. Lift up and fasten the gear cable in the coolant reservoir bracket on the bulkhead.
27. Remove the cable holder (C) from the gearbox.
28. Unplug the connector of the rear oxygen sensor (A).
29. Lift up the heat shield (B) and remove the rear oxygen sensor (C). Use 83 96 350 Removal socket, oxygen sensor.
30. Unplug the connector of the upper oxygen sensor (A) and move up the cable (B).
31. Carefully raise the heat shield slightly. Use 83 96 350 Removal socket, oxygen sensor when removing the oxygen sensor (C).
32. Position a jack under the gearbox.
33. Mark the position of the bolts and undo the left engine mounting (A). Carefully release the engine down onto the subframe.
Manual Transmission:
Automatic Transmission:
34. Remove the nuts (A). Lubricate the studs and nuts with rust removal oil.
35. Remove the catalytic converter from the bracket (B) and move it aside.
36. Remove the bracket bolts and nut (C).
37. Carefully coax up the catalytic converter (A) as illustrated.
Position 1 (A1)
Position 2 (A2)
Position 3 (A3)
To fit
1. Position the catalytic converter.
2. Fit the bracket bolts and nut (C).
Tightening torque 42 Nm (31 ft. lbs.)
3. Insert the lower bolt (B) in the bracket.
IMPORTANT: When fitting the front catalytic converter to the turbocharger, tighten the nuts in a crosswise pattern to avoid tightening the flange crooked.
4. Fit the flange using new nuts (A). Coat the studs with 90 513 210 Universal paste. Tighten the nuts alternatingly.
5. Tighten the bolt (B) in the bracket.
Tightening torque, nuts: 25 Nm (18 ft. lbs.)
Tightening torque, bolt 19 Nm (14 ft. lbs.)
6. Raise the engine with the jack and mount the left engine mounting (A) following the mark.
Tightening torque 80 Nm (59 ft. lbs.).
Manual Transmission:
Automatic Transmission:
7. Remove the jack.
8. Fit the upper oxygen sensor (C).
Tightening torque 45 Nm (33 ft. lbs.).
9. Secure the cable (B) and plug in the connector (A).
10. Fit the rear oxygen sensor (C).
Tightening torque 45 Nm (33 ft. lbs.).
11. Plug in the connector of the rear oxygen sensor (A).
12. Fit the cable holder (C) to the gearbox.
13. Manual Transmission: Fit the gear cables (B) to the cable holder and attach them to the shifter arms (A).
14. Automatic Transmission: Fit the gear cable (B) to the cable holder and attach it to the shifter arm (A).
15. Fit the cable duct to the gearbox (E).
Manual Transmission:
Automatic Transmission:
16. Fit the turbocharger coolant return pipe (D). Fit the banjo screw using new gaskets.
Tightening torque 30 Nm (22 ft. lbs.)
17. LHD: Fit the brake servo heat shield (C).
Tightening torque 8 Nm (6 ft. lbs.)
18. Fit the heat shields to the catalytic converter (B) and turbocharger (A).
19. Fit the quick coupling (C) of the coolant hose and plug in the level sensor connector (B). Press the coolant reservoir into the bracket on the bulkhead.
20. Attach the hoses (A) to the expansion tank.
21. Fit Battery cover, bottom, B284 .
22. Raise the car.
23. Fit the bracket (C) to the front catalytic converter and oil sump.
Tightening torque to oil sump: 23 Nm (17 ft. lbs.)
Tightening torque to exhaust pipe flange: 40 Nm (30 ft. lbs.)
24. Mount the cable fixing (B) and plug in the oil level sensor connector (A).
25. RHD: Fit Alternator, B284, 4WD, (RHD).
26. LHD: Fit the alternator retaining bolts (B). Carefully move the engine to the left slightly if necessary.
27. LHD: Connect the electrical connections (A) of the alternator.
28. LHD: Relieve the load on the belt tensioner with a 1/2 inch puller (B) and fit the belt.
29. LHD: Fit the right wing liner (A).
30. Fit Rear catalytic converter, B284, 4WD.
31. Lower the car.
32. Fit the battery negative cable.
33. Carry out Cooling system pressure testing and Bleeding and charging the cooling system, B284.
34. Fit the upper engine cover and battery cover.
35. Carry out Procedures after reconnecting the battery.