2004 Catalytic Converter replacement procedure?

[rpcc]

Hello - What's the procedure for replacing the catalytic converters with new oem ones?  How long should this take?  Dealer is quoting 10 hrs

[clarksongli]

Which cats? I'm assuming the front set and not the secondary ones?

10 hrs is probably standard....remember the front downpipe and cat is integral.....removal probably does take some effort.

Why are you replacing the cats?

[rpcc]

Thanks for the reply - 

 

Front Cats.  I took it to the dealer to get them to diag.  Its amazing it take that long to replace these - 10 hrs is a long time.  BTW, Its an 04S with 72k.  

[mbagge01]

I am curious about this also. I am considering putting larger primary cats in, and leistung on there website states that the porsche book time is 120 minutes per side. Does it require dropping the engine? Is this something that could be taken on as a DIY with special tools.

[rpcc]

2 hours per side sounds realistic.  Per the dealer it does not require dropping the engine.  I'd love to see a diy on this as well to see what's involved.  From what I can tell, you need to unbolt both ends and remove the o2 sensor and then reinstall.  10 hour seems like a very long time for this.

[Loren]

Porsche book time 270 time units per side.

100 time units equal 1 hour.
 

Time to get another quote or DIY.

[mbagge01]

Loren, is this a procedure that can be done from underneath the car with extension wrenches. Is there a lot of parts that need to be removed to replace the primary cats

[Loren]

The primary cats are removed by removing the wheel and the engine cover. Aceess through the wheel opening and engine compartment.

[rpcc]

Many thanks Loren for jumping in here.  Can you post the workshop instructions or tell me where to find them in the manuals.  

 

I'm sure many of the member here will be replacing their cats at some point so a DIY would be very helpful.  

 

Thanks

[Loren]

I sent you a PM.

[paulwu]

Hi Loren,

 

I am about to replace the flex pipes on 04 Cayenne-S that needs to remove the Cat; however, it seems impossible to reach nor even seeing the bolts that connects from the headers. Can you please help with workshop instructions?!  Thanks in advanced!

[Loren]

I sent you a PM.

[G. Joe Boyle]

I'm also looking for the procedure to remove and replace my downpipes on my 2009 Porsche 957  Cayenne Turbo S. Any help would be greatly appreciated

[padimx]

Hi Loren,

 

I am about to replace the flex pipes on 05 Cayenne-S that needs to remove the Cat; however, it seems impossible to reach nor even seeing the bolts that connects from the headers. Can you please help with workshop instructions?!  Thanks in advanced!

[FHS72]

Hi everyone, I'm new here, it's a great forum, many thanks to all who are working to make it useful. I'm interested in the same procedure but for the 04 Cayenne turbo version, is it the same or deferent way to do it. Thanks

[Martynb]

Hello All

 

another one looking to do this procedure. My passenger side flex pipe started leaking. Any info or diy would be sooo helpful... tia

[paulwu]

18 minutes ago, Martynb said:

Hello All

 

another one looking to do this procedure. My passenger side flex pipe started leaking. Any info or diy would be sooo helpful... tia

I have done my MY04 Cayenne-S replaced both sides with the aftermarket flex pipes ordered on Ebay. It is kind of impossible to DIY unless replacing with complete OEM part, since it requires professional welding that need twisting angle welding to flex pipes. I sent to a bodyshop friend in Montreal and charged me 7 hours labor.

 

Very poor design in exhaust system including to change O2 sensors. If you got chance to do the flex pipes job remember to change O2 sensors at the same time. Hope it helps; good luck!

[quip11]

Hello, I too am faced with most likely replacing my catalytic converters on my 08 GTS with 128K miles. I have P0421 and P0431 codes. I already replaced all 4 O2 sensors, but the codes came back. So far, I've replaced thermostat, thermostat housing and updated the coolant lower pipe in the process as well. I've searched and ran out of other options on how to get rid of these codes. I'd appreciate any other suggestions or expertise anyone may have on this matter. If you could share some workshop instructions on performing this task, thank you.

[Mbrink44]

Hi All/Loren,

 

Anyone with some DYI information on this would be greatly appreciated. Just bought an after market set up to for the pass side of my 2009 Cayenne S (124K miles).  It is leaking pretty bad from the flex pipe.  Please send info or reply here.  mbrink44@yahoo.com

 

This is the aftermarket one. $344 shipped.   I have already received it.   https://www.carid.com/dec/exhaust-pipe-mpn-po2625p.html?singleid=140268005?utm_source=email&utm_medium=order&utm_campaign=order_notification_mail

 

Thanks

Mark

[95_993]

Need to replace flex pipe as well.  Can anyone PM and the Procedure?

[mikenelson78]

I need to replace the flex pipe in the passenger side of my 2004 Cayenne S. Can someone please pm me the shop instructions on how to do so. Thanks in advance!

Mike

[Grant Kallevig]

Another one here in need of replacing the passenger side flex pipe. If anyone has a DIY writeup please send. Thanks in advance!

[galognu]

Hi,

 

I have a 2008 Cayenne GTS.  Nice size rip/hole at end of flex pipe on passenger side.  Been doing research into what to do next.  I noted a few people ask for DIY instructions and also noted one of the Admins...Loren potentially being able to supply that?

 

So I also would appreciate if you have any helpful hints, instructions.

 

I will be taking it to my local muffler shop to see if can cut out section and reweld without having to remove entire cat pipe.  Will keep updates.

 

Thank you

[galognu]

OMGOMGOMG.  My flex pipes were totally gone.. I had massive leaks on both sides.  Had read through all options and went to my local guy.  Cut off flex pipes and secondary cats.  2.5 inch stainless steel pipes with small flex pipe.  Completely different beast.  Price for parts and what dealer would charge is incomparable inked u can burn money without worry.  

[galognu]