Catalytic Converter - 2.3L Pzev Manifold

Catalytic Converter - 2.3L PZEV Manifold

Special Tool(s):

Material:

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.
2. Remove the generator air inlet duct.





3. Disconnect the heated oxygen sensor (HO2S) and 2 catalyst monitor sensor (CMS) electrical connectors.
4. Remove the wiring harness bracket off the stud and position it aside.
5. Remove the 2 catalytic converter manifold-to-exhaust flexible pipe nuts.
^ Discard the gasket and the 2 nuts.

6. Remove the 4 heat shield bolts and the heat shield.
7. Remove the 2 catalytic converter manifold shield bracket bolts and the bracket.
8. Loosen the 2 catalytic converter manifold bracket bolts.
9. Disconnect the secondary injection hose from the catalytic converter manifold.





10. NOTE: If installing a new catalytic converter manifold, remove the heated oxygen sensor (HO2S) and the catalyst monitor sensors for installation in the new catalytic converter manifold.

Using the special tool, remove the HO2S and 2 CMS.





11. Remove the 7 catalytic converter manifold nuts and remove it from the vehicle.
^ Discard the 7 nuts and the gasket.

12. Clean and inspect the manifold.
13. Remove and discard the 7 catalytic converter manifold studs.

Installation

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

Inspect the catalytic converter manifold for warpage across the manifold flange area.
2. Install the 7 new catalytic converter manifold studs.
^ Tighten to 17 Nm (13 ft. lbs.).

3. Position a new catalytic converter manifold gasket on the studs.

4. 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.).





5. NOTE: Apply anti-seize lubricant to the threads of the sensors before installation.

If installing a new converter, install the HO2S and the 2 CMS using the special tool.
^ Tighten to 47 Nm (35 ft. lbs.).





6. Connect the secondary injection hose to the catalytic converter manifold.





7. Tighten the 2 catalytic converter manifold bracket bolts.
^ Tighten to 20 Nm (15 ft. lbs.).

8. Install the 2 catalytic converter manifold shield bracket bolts and the bracket.
^ Tighten to 20 Nm (15 ft. lbs.).

9. Position the heat shield and install the 4 heat shield bolts.
^ Tighten to 10 Nm (89 inch lbs.).

10. Install the 2 catalytic converter manifold-to-exhaust flexible pipe nuts.
^ Install a new gasket.
^ Tighten to 40 Nm (30 ft. lbs.).

11. Position the wiring harness bracket on the stud.
12. Connect the HO2S and 2 CMS electrical connectors.
13. Install the generator air inlet duct.