Front catalytic converter, B284, 4WD

/ 9-3 (9440) / 2010 / 2. Engine / V6 petrol / Exhaust emission control system / Adjustment/replacement / 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°.

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 ½" 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). Man: Aut:

23.	Man: Lift the cable connections (A) off of the gearbox shifter arm.

24.	Man: Detach the gear cables (B) from the gearbox cable holder.

25.	Aut: Lift the cable connection (A) off of the gearbox shifter arm.

26.	Aut: 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. Man: Aut:

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 lbf ft)

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 lbf ft) Tightening torque, bolt 19 Nm (14 lbf ft)

6.	Raise the engine with the jack and mount the left engine mounting (A) following the mark. Tightening torque 80 Nm (59 lbf ft). Man: Aut:

7.	Remove the jack.

8.	Fit the upper oxygen sensor (C). Tightening torque 45 Nm (33 lbf ft).

9.	Secure the cable (B) and plug in the connector (A).

10.	Fit the rear oxygen sensor (C). Tightening torque 45 Nm (33 lbf ft).

11.	Plug in the connector of the rear oxygen sensor (A).

12.	Fit the cable holder (C) to the gearbox.

13.	Man : Fit the gear cables (B) to the cable holder and attach them to the shifter arms (A).

14.	Aut: 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). Man: Aut:

16.	Fit the turbocharger coolant return pipe (D). Fit the banjo screw using new gaskets. Tightening torque 30 Nm (22 lbf ft)

17.	LHD: Fit the brake servo heat shield (C). Tightening torque 8 Nm (6 lbf ft)

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 lbf ft) Tightening torque to exhaust pipe flange: 40 Nm (30 lbf ft)

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 ½" 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 .

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