Once fitted and the engine started, the part is no longer refundable.
Note! Exhaust gases are dangerous. Good ventilation is essential if the engine is running in the garage, even if only for a short period of time.
ITEMS TO CHECK BEFORE ASSEMBLY (defects that led to damage of the replaced CATALYST)
| Test stage : | Checked on : | Replaced on : | Comments : |
|---|---|---|---|
| Lambda sensor | |||
| Spark plugs | |||
| Turbo | |||
| Ignition coil | |||
| Gaskets, clamps and screws | |||
| Sealing | |||
| Adblue injector (SCR) |
CATALYST ASSEMBLY INSTRUCTIONS - Catalytic Converter (for PROs only)
Note! To avoid accidents, the safety measures and devices required at the installation site must be in accordance with the instructions and rules for safety at work.
| REMOVAL OF THE OLD CATALYST : | ASSEMBLY OF THE NEW CATALYST : |
| 1 Disconnect the grounding plug from the battery. | 1 Thoroughly clean the mounting anges/hoses to ensure a gas-tight connection to the new catalyst. Under no circumstances should sealant or paste be used, as this could potentially degrade the performance of the catalyst. Install new gaskets and xing bolts. |
| 2 Lift the vehicle and ensure that it is securely locked in position. | 2 Fit the new catalytic converter. An arrow on the catalytic converter shell illustrates the correct direction of the exhaust gases. Fit the lambda sensor if applicable. Before tightening the xing bolts to the final tension, make sure that the catalytic converter has room to move without touching the vehicle body. |
| 3 Carefully loosen and remove the lambda sensor from the catalytic converter if it is fitted. | 3 Lower the vehicle to the ground, connect the battery ground and make sure the exhaust system is rigid. |
| 4 Loosen the catalyst fixing bolts. If they are stuck, spray oil on the rust and/or heat the bolts with a gas torch. If using a torch, ensure that it does not burn the underside of the car and that the relevant health and safety guidelines are followed. | |
| 5 Remove the fixing screws and the old catalyst. |
One of the main problems with many types of emissions is that a new catalyst in good condition can and will mask the real problem.
Diagnose the cause of the problem that led to the catalyst being changed and make repairs before fitting the new catalyst, otherwise it will not work properly. Possible causes are: excess unburned fuel and overheating in the catalyst, misring, ignition system failure, towing, malfunctioning spark plugs or spark plug wire (petrol models). Other causes may be oil or antifreeze entering the exhaust or sealing compounds that may have contaminated the catalyst core, lambda sensor failure (gasoline models) or broken exhaust system hangers.
The choice of unsuitable fuel can also destroy the catalyst. If the catalyst is fitted to a vehicle that has been fuelled with leaded petrol, it is recommended that the fuel system is cleaned by driving ~1000 km on unleaded fuel before fitting the new catalyst.