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Pelican Technical Article:

Catalytic Converter Replacement

Jared Fenton

Time:

2 hours2 hrs

Tab:

$1000

Talent:

****

Tools:

13mm & 16mm sockets, penetrant oil

Applicable Models:

Jetta MkIV 2.0L (1998-05)

Parts Required:

Catalytic converter

Hot Tip:

Soak all the fasteners with penetrant oil before starting

Performance Gain:

Cleaner running car

Complementary Modification:

Replace muffler

The catalytic converter is a major part of the emissions system on your car. It works by changing harmful exhaust gases into more environmentally friendly byproducts. Inside the converter is a series of baffles made of platinum, palladium and other rare metals. When the exhaust gases hit the baffles, there is a chemical reaction and the gases are converted.

Over time, catalytic converters can become saturated due to incorrect fuel mixtures. The elements inside the converter can also be damaged and break from impact. A saturated or blocked catalytic converter typically emits a sulphur-like smell from the exhaust. There may also be a loss of power under load. In these cases, the converter must be replaced. In this article, I'll go over the steps involved with replacing the converter on your VW Jetta.

Accessing the catalytic converter requires going underneath the car. You'll need to jack the car up at both ends and secure it on jack stands. See our article on Jacking up Your Mk4 Jetta for more information.

Shown here is a new catalytic converter for the Mk4 Jetta.
Figure 1

Shown here is a new catalytic converter for the Mk4 Jetta. Pelican Parts can provide you with a new catalytic converter if yours is on the way out.

Loosen and remove the rear oxygen sensor (green arrow) from the catalytic converter.
Figure 2

Loosen and remove the rear oxygen sensor (green arrow) from the catalytic converter. See our article on Oxygen Sensor Replacement for more information.

Loosen and remove the two 16mm nuts (green arrows) holding the clamp in place over the two sections of exhaust.
Figure 3

Loosen and remove the two 16mm nuts (green arrows) holding the clamp in place over the two sections of exhaust. I highly recommend spraying down the area with penetrant oil a few days before starting. This will help when trying to loosen the clamp. Once the nuts are loose, slide back the clamp to release the rear of the catalytic converter.

Now loosen and remove the four 13mm nuts (green arrows) holding the catalytic converter to the exhaust manifold.
Figure 4

Now loosen and remove the four 13mm nuts (green arrows) holding the catalytic converter to the exhaust manifold. Again, it's a good idea to spray these beforehand with penetrant oil.

The last step is to loosen and remove the two 13mm nuts (green arrows) holding the rubber mount (yellow arrow) to the chassis.
Figure 5

The last step is to loosen and remove the two 13mm nuts (green arrows) holding the rubber mount (yellow arrow) to the chassis. Once free, pull the rubber off the old cat and transfer it to the new one. At this point, you're ready to install the new cat. Installation is the reverse order of removal.

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Page last updated: Mon 12/5/2016 03:06:19 AM