Catalytic Converter: Service and Repair

Exhaust System:

Spring Clamps:

REMOVAL
- Remove oxygen sensor.
- Remove heat shield bolts from convertor front pipe.

WARNING: The next operation involves removing exhaust spring clamps. These clamps have extremely high tension and may cause serious injury if handled incorrectly. To avoid personal injury, use of VW special tool #3140 (expanding wedge set) is highly recommended.

Spring Clamp Removal:

- Drive short wedge into exhaust clamp.
- Push front pipe to one side. Remove clamp and wedge as a unit using locking pliers.
- Repeat operation to remove remaining clamp.
- If re-using clamps, leave wedges in place.

Removing Wedge:

- If replacing clamps, use long starter wedges to remove short wedge.
- Loosen clamping sleeve and slide back.
- Remove convertor.

INSPECTION
- Visually inspect exterior of converter. If severe damage is noted, such as dented, crushed or rusted out shell, replace converter.
- Whenever converter is removed from vehicle, check ceramic element through exhaust inlet. If element is clogged, melted or otherwise damaged, replace converter.

INSTALLATION
- Install convertor into clamping sleeve.
- Position front pipe in exhaust manifold.
- Push exhaust pipe to one side and install spring clamp. Leave wedge in place.
- Push exhaust to other side and install remaining clamp.
- Carefully drive out wedges.
- Align and tighten clamping sleeve.
- Install front pipe heat shield.
- Reinstall oxygen sensor.