Catalytic Converter - Manifold

Catalytic Converter - 2.3L Manifold

Special Tool(s):

Removal

1. NOTE: Always install new fasteners and gaskets. Clean flange faces prior to new gasket installation to make sure of proper sealing.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Disconnect the battery ground cable. For additional information, refer to Battery.





3. Remove the generator air inlet duct.
4. Remove the heated oxygen sensor (H02S) and catalyst monitor sensor (CMS). For additional information, refer to Computers and Control Systems.
5. Remove the wiring harness bracket off the stud and position it aside.
6. Remove the 2 catalytic converter manifold-to-exhaust flexible pipe nuts.
^ Discard the gasket and the 2 nuts.
7. Remove the 6 heat shield bolts and the heat shield.
8. Remove the 2 catalytic converter manifold shield bracket bolts and the bracket.
9. Loosen the 2 catalytic converter manifold bracket bolts.
10. Remove the 7 catalytic converter manifold nuts and remove it from the vehicle.
^ Discard the 7 nuts and the gasket.
11. Remove and discard the 7 catalytic converter manifold studs.

Installation

1. CAUTION: If the warpage is greater than 0.76 mm (0.03 inch), replace the catalytic converter manifold.

Inspect the catalytic converter manifold for warpage across the manifold flange area.
2. Clean the mating surfaces of the cylinder head and the catalytic converter manifold.
3. Install the 7 new catalytic converter manifold studs.
^ Tighten to 17 Nm (13 ft. lbs.).
4. Position a new catalytic converter manifold gasket on the studs.

5. CAUTION: Failure to tighten the catalytic converter manifold nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.

CAUTION: Failure to tighten the catalytic converter manifold nuts to specification a second time will cause the converter to develop an exhaust leak.

NOTE: Make sure to tighten the nuts in the sequence in 2 stages.





Position the catalytic converter manifold and tighten the 7 new nuts in the sequence shown, in 2 stages.
^ Stage 1: Tighten to 55 Nm (41 ft. lbs.).
^ Stage 2: Tighten to 55 Nm (41 ft. lbs.).
6. Install the 2 catalytic converter manifold shield bracket bolts and the bracket.
^ Tighten to 20 Nm (15 ft. lbs.).
7. Tighten the 2 catalytic converter manifold bracket bolts.
^ Tighten to 20 Nm (15 ft. lbs.).
8. Position the heat shield and install the 4 heat shield bolts.
^ Tighten to 10 Nm (89 inch lbs.).
9. Install the 2 catalytic converter manifold-to-exhaust flexible pipe nuts.
^ Install a new gasket.
^ Tighten to 40 Nm (30 ft. lbs.).
10. Position the wiring harness bracket on the stud.
11. Install the heated oxygen sensor (HO2S) and catalyst monitor sensors (CMS). For additional information, refer to Computers and Control Systems.





12. Install the generator air inlet duct.
13. Connect the battery ground cable. For additional information, refer to Battery.