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Pelican Technical Article:
Catalytic Converter Replacement

Steve Vernon

 
Time: 3 hours
Tab: $5-$30
Talent:  
Tools:
6mm, 5mm Allen, 13mm, 12mm wrench and socket, extensions and universal joints
Applicable Models:
Touareg (2004-07)
Parts Required:
Exhaust gaskets
Hot Tip:
Take your time, it is a tight fit
Performance Gain:
Quieter vehicle
Complementary Modification:
Oil Change
 
   

   
Check out some other sample projects from the book: 
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     The exhaust manifolds on the Volkswagen Touareg run off the right side of the motor, and even though the motor is referred to as a "V" both manifolds are on the same plane. Some of the exhaust studs may come out for the head while removing the manifold, but as long as none of them break off on the head you can just reinstall them.

     Begin by soaking everything in penetrating oil. It's best if you can do this before you attempt to remove everything. The bolts are hidden by the heat shield so you really can't get at them with penetrating oil until you have removed this.

     Note: You are going to be working on the exhaust system so make sure the car is cold while you are doing this. Also give yourself enough time as you will not be able to use the car until the job is complete. Take pictures as you go and watch your hands when breaking things loose as it is all a very tight fit.

     Over the years your car may have been serviced by multiple people including previous owners and this can lead to parts replaced with different size fasteners and hardware. The sizes of the nuts and bolts we give may be different from what you have so be prepared with different size sockets and wrenches. If something is different on your vehicle please let us know and share your info to help other users. If you have any questions or comments or even a different procedure you would like to share please leave it below and please include your vehicle information.
The down pipe connects to the two exhaust manifolds and runs down between the engine and the chassis on the right side of the motor (red arrow).
Figure 1
The down pipe connects to the two exhaust manifolds and runs down between the engine and the chassis on the right side of the motor (red arrow).
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Begin by removing the air filter lid, MAF and intake tube.
Figure 2
Begin by removing the air filter lid, MAF and intake tube. Please see our article on these procedures for additional assistance.
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Remove the front engine cover by pulling straight up on it (red arrow).
Figure 3
Remove the front engine cover by pulling straight up on it (red arrow).
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Disconnect the vacuum hose that is connected to the tube that runs along the heat shield by squeezing the end and separating them.
Figure 4
Disconnect the vacuum hose that is connected to the tube that runs along the heat shield by squeezing the end and separating them.
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Use a 5mm Allen (red arrow) and remove the two bolts holding the tube to the manifold, then use a 6mm Allen and remove the bracket to manifold bolt (yellow arrow).
Figure 5
Use a 5mm Allen (red arrow) and remove the two bolts holding the tube to the manifold, then use a 6mm Allen and remove the bracket to manifold bolt (yellow arrow).
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Remove the three bolts holding the heat shield to manifold bracket and remove the bracket (red arrow).
Figure 6
Remove the three bolts holding the heat shield to manifold bracket and remove the bracket (red arrow).
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Remove the two 5mm Allen bolts holding the vacuum tube to the pump below the throttle body (yellow arrow) making sure to replace the gasket when installing and remove the vacuum pipe from the heat shield.
Figure 7
Remove the two 5mm Allen bolts holding the vacuum tube to the pump below the throttle body (yellow arrow) making sure to replace the gasket when installing and remove the vacuum pipe from the heat shield.
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Using a 5mm Allen and long extension remove the forward bolt holding the heat shield to engine (red arrow).
Figure 8
Using a 5mm Allen and long extension remove the forward bolt holding the heat shield to engine (red arrow).
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Disconnect and remove the throttle body, please see our article on throttle body removal for additional assistance.
Figure 9
Disconnect and remove the throttle body, please see our article on throttle body removal for additional assistance.
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With the throttle body out you can remove the rear 5mm Allen bolt (red arrow) holding the rear of the heat shield.
Figure 10
With the throttle body out you can remove the rear 5mm Allen bolt (red arrow) holding the rear of the heat shield.
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Carefully remove any vacuum lines in your way and remove the heatshield.
Figure 11
Carefully remove any vacuum lines in your way and remove the heatshield.
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Check your hardware and remove the three nuts holding the bank 1-3 (red arrow) and 4-6 (yellow arrow) exhaust manifold to cat pipe.
Figure 12
Check your hardware and remove the three nuts holding the bank 1-3 (red arrow) and 4-6 (yellow arrow) exhaust manifold to cat pipe.
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There is a bracket that attaches the cats to the engine, check the hardware (ours was 13mm) and remove the bracket support.
Figure 13
There is a bracket that attaches the cats to the engine, check the hardware (ours was 13mm) and remove the bracket support.
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You now have access to the two exhaust manifolds; the forward one for banks 1-3 (red arrow) and the rear for banks 4-6 (yellow arrow).
Figure 14
You now have access to the two exhaust manifolds; the forward one for banks 1-3 (red arrow) and the rear for banks 4-6 (yellow arrow). Use a 12mm deep socket and remove the nuts.
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Due to the crimping nature of the nuts, sometimes the studs will come out from the head (yellow arrow) and sometime the studs will stay (red arrow).
Figure 15
Due to the crimping nature of the nuts, sometimes the studs will come out from the head (yellow arrow) and sometime the studs will stay (red arrow). This is normal and as long as the stud does not break off in the head you can just reinsert the studs.
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Check the condition and placement of the studs on the manifold that attaches to the down pipe (red arrow) before reinstalling.
Figure 16
Check the condition and placement of the studs on the manifold that attaches to the down pipe (red arrow) before reinstalling.
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Installation is the reverse of removal and do not forget to replace the gaskets to the down pipe.
Figure 17
Installation is the reverse of removal and do not forget to replace the gaskets to the down pipe. You only need to replace the gaskets on the down pipe that you disconnect, if you do not disconnect the lower connection you do not need to replace that gasket.
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Need to buy parts for this project?
Click here to order parts for your Volkswagen from our parts catalog
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  Applies to: Touareg (2004-07)
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