Replacing a plugged (clogged) catalytic converter | 
How to remove the catalytic converter

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  • OVERALL DIFFICULTY INDEX: 5/10
  • IF YOU HAVE NO TOOLS, YOU PAY $100 TO GET THEM FOR THIS JOB
  • IF YOU HAVE NO EXPERIENCE YOU SPEND 2 HOURS TO CARRY OUT THIS JOB
  • NO SAFETY ISSUES WHEN INTERVENING ON A COLD ENGINE​
BEFORE YOU START
  • The below is needed for replacing the catalytic converter and for removing the turbo.
  • You may also visit our page for catalytic converter diagnostic.
  • A specific tool exists for the exhaust clamps, but you an manage with large retaining ring pliers.
  • Make sure to pay a good attention to the radiator, not to damage its fins while working on the exhaust. You may fix a temporary carton board panel.
  • Do not intervene unless the engine is completely cold. 
DISCLAIMER:
Our pictorials are of informative nature and do illustrate works carried out by ourselves at our own premises for our own use and satisfaction.
Readers who envisage to carry out similar works inspired by the below method shall do this at their own risks and liability.
The below works concerned a Peugeot 5008 equipped with a turbo-charged PSA BMW EP6 engine.
Same or similar engine and turbos can be found on Peugeot 207, 208, 308, 508, 3008, 5008 and Citroen C4, C4 Sedan, DS3, DS4, DS5 also the Mini Cooper S. The works remain similar to almost any catalytic converter mounted in the front of the vehicle between engine and radiator.

Dismantling a collector mounted catalytic converter 

1- If your vehicle is equipped with a turbo, start by removing the air hose between the turbo and inter-cooler.
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2- Unscrew the air mixture sensor with a flat spanner size 22. It is better to use however the specific grooved socket size 22.
3- Unclip and remove small thermal shields that hide or mount on top of the main shield.
4- Unscrew the top part of the thermal shield and remove it. Be careful not to damage the radiator.
5- Lift the vehicle.
6- Use two jacks on each side for safety. Keep the wheels.
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7- Unscrew and remove the lower part of the main thermal shield. You might not be able to extract it yet, leave it hanging on the catalytic converter.  
8- Remove the screws that hold the converter to the turbo.
9- Keep one of them, the one with the easiest reach.
10- Unscrew the O2 sensor and lower bolt that holds the converter against the engine block.
11- Unscrew and open the connecting clamp (collar) to the exhaust line. A specific tool exists but you can manage without it. Use long nose pliers and a big slotted screwdriver instead.
12- Now remove the last bolt still holding the converter to the turbo and carefully...
13- ...hold the converter down to the ground (do not drop it!) and extract it from beneath the vehicle.
14- Proceed to the turbo replacement if this was the purpose of your intervention or replace the converter with a new one and reverse the above steps. It is mandatory to replace the gasket between converter and turbo.

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See also our complete EP6 engine repair manual:

And more DIY tips for all types of cars: