Catalytic converter

F9Q

Tightening torques
turbocharger exhaust manifold nuts	2.6 daN.m
exhaust flange studs	0.7 daN.m
exhaust flange nuts	2.1 daN.m
catalytic converter bracket fixing bolts and nuts, flywheel end	2.1 daN.m
catalytic converter bracket nut, timing end	3 daN.m
catalytic converter bracket fixing bolt, timing end	5 daN.m
catalytic converter bracket fixing bolts and nuts, flywheel end	2.1 daN.m
torque rod bolt on the engine	18 daN.m
torque rod bolt on the subframe	10.5 daN.m
exhaust line support fixing bolt to the body	2.1 daN.m

REMOVAL

• Position the vehicle on a two-post lift.
• Disconnect the battery.
• Remove:

• the front right wheel,
• the engine undertray.

• Remove the two exhaust flange nuts (1).

Note: Mark the position of the exhaust flexible mount brackets on the body with a marker.

• Remove the fixing bolt (4) of the exhaust line rubber mounting to the body.

• Remove:

• the fixing bolt (5) of the silencer rubber mounting.

• Move the exhaust line rearward.

• Remove the four fixing bolts (2) of the catalytic converter bracket.

• Remove:

• the fixings (6) of the catalytic converter bracket,
• the catalytic converter bracket.

• Remove the torque reaction rod (3).

• Remove:

• the engine lifting lug,
• the three fixing nuts (7) of the catalytic converter on the turbocharger,
• the catalytic converter from underneath the vehicle.

INSTALLATION

• Strictly observe the fitting order of the catalytic converter brackets.

WARNING Always replace the gaskets with new ones.

• Refit and torque the catalytic converter fixing nuts on the turbocharger (2.6 daN.m).
• Tighten to the following torques:

• the exhaust flange studs (0.7 daN.m),
• the exhaust flange nuts (2.1 daN.m),
• the catalytic converter bracket fixing bolts and nuts, flywheel end (2.1 daN.m).

• Refit the catalytic converter brackets, observing the order carefully.

Refitting the timing end bracket

• Refit:

• fit the bracket by hand-tightening (without locking) the nut (8) and the bolt (9),
• Tighten in the following order and to the following torques:

catalytic converter bracket nut, timing end (3 daN.m) (8),
catalytic converter bracket fixing bolt, timing end (5 daN.m) (9).

Refitting the flywheel end bracket

• Refit the fixing bolts of the relevant bracket by hand, in the tightening order.
• Tighten in the following order and to the following torques:

• catalytic converter bracket fixing bolts and nuts, flywheel end (2.1 daN.m),
• the torque rod bolt on the engine (18 daN.m),
• the torque reaction rod bolt to the subframe (10.5 daN.m).
• the exhaust line support fixing bolt to the body (2.1 daN.m),

• Refit in the reverse order of removal.
• Check that all the heat shields of the exhaust line are present and correctly fixed.
• Check that there is no contact with the underbody.

WARNING

• Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).
• Do not reuse a used sleeve.
• The sleeve clamping bolt and nut assembly must be oriented so as to avoid any contact with the underbody.
• Replace any damaged heat shield without fail.

K9K

Tightening torques
turbocharger exhaust manifold nuts	2.6 daN.m
exhaust flange studs	0.7 daN.m
exhaust flange nuts	2.1 daN.m
catalytic converter bracket fixing bolts and nuts, flywheel end	2.1 daN.m
side bracket fixing bolt on the catalytic converter	2.5 daN.m
side support bracket mounting screw on the engine	4.4 daN.m
fixing bolt of the exhaust gas recirculation solenoid valve heat shield	1.2 daN.m
exhaust line support fixing bolt to the body	2.1 daN.m

REMOVAL

• Position the vehicle on a two-post lift.
• Disconnect the battery.
• Remove the undershield.

• Remove:

• the exhaust flange fixings (1),
• the bracket fixing (2) on the catalytic converter,

• Loosen the other bracket fixings on the gearbox,
• Remove the bracket (3).

Note: Mark the position of the exhaust flexible mount brackets on the body with a marker.

• Remove the fixing bolt (4) of the exhaust line rubber mounting to the body.

• Remove the fixing bolt (5) of the silencer rubber mounting.
• Move the exhaust line rearward.

• Remove:

• the catalytic converter bracket (6),
• the four fixing nuts (7) of the catalytic converter on the turbocharger,
• the catalytic converter.

INSTALLATION

• Refit:

• the catalytic converter,
• the sleeve (Exhaust chapter, Exhaust general information, page 19B-1).

• Bring the catalytic converter fixing bolts close.
• Refit in the reverse order of removal.

WARNING

Always replace:

• the exhaust flange gasket,
• all plastic air intake hoses disconnected,

• Tighten to the following torques:

• Catalytic converter mounting nuts to the turbocharger (2.6 daN.m),
• the exhaust flange studs (0.7 daN.m),
• the exhaust flange nuts (2.1 daN.m),
• catalytic converter bracket fixing bolts and nuts, flywheel end (2.1 daN.m),
• Side stand mounting bolt to the catalytic converter (2.5 daN.m),
• the side stand mounting bolts on the engine (4.4 daN.m),
• EGR solenoid valve heat shield mounting bolts (1.2 daN.m),
• Exhaust line bracket mounting bolt to the body (2.1 daN.m).

• Refit the engine undertray.
• Check that there is no contact with the underbody.

WARNING

• Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).
• Do not reuse a used sleeve.
• The sleeve clamping bolt and nut assembly must be oriented so as to avoid any contact with the underbody.
• Replace any damaged heat shield without fail.

F4R or K4J or K4M

Essential special tools
Tool 1495-01	24 mm socket for removing / refitting oxygen sensors - 1/2" square drive and 24 mm external hex

Tightening torques
oxygen sensor	4.5 daN.m
exhaust flange studs)	0.7 daN.m
exhaust flange nuts)	2.1 daN.m

REMOVAL

• Position the vehicle on a two-post lift.
• Disconnect the battery.
• Remove:

• the engine undershield,
• the oxygen sensor.

• Cut the exhaust line (Exhaust chapter, Exhaust general information, page 19B-1) (Exhaust chapter, Exhaust general information, page 19B-4)

• Remove:

• exhaust flange mounting nuts (1),
• the catalytic converter.

INSTALLATION

• Refit the oxygen sensor.
• Tighten the oxygen sensor to torque (4.5 daN.m) using tool (Mot. 1495-01),
• Refit and tighten the exhaust flange studs to torque (0.7 daN.m),
• Replace the exhaust flange gasket.
• Refit:

• the catalytic converter,
• the sleeve (Exhaust chapter, Exhaust general information, page 19B-1).

• Refit the catalytic converter mounting nuts.
• Tighten the exhaust flange nuts to torque (2.1 daN.m)
• Tighten the coupling while relieving the exhaust line to ensure correct alignment.
• Reconnect the oxygen sensor.
• Check that all heat shields on the exhaust line are present and correctly secured.
• Refit the engine undertray.
• Check that there is no contact with the underbody.

WARNING

• Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).
• Do not reuse a used sleeve.
• The sleeve clamping bolt and nut assembly must be oriented so as to avoid any contact with the underbody.
• Replace any damaged heat shield without fail.
• After each catalytic converter replacement, carry out a road test.