Catalytic Converter - PZEV Manifold

Catalytic Converter - 2.3L PZEV Manifold

Removal

1. NOTE: Always install new fasteners and gaskets as indicated. 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 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. 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.
12. Clean and inspect the catalytic converter manifold.

Installation
1. Install the 7 new catalytic converter manifold studs.
^ Tighten to 17 Nm (13 lb-ft).
2. Position a new catalytic converter manifold gasket on the studs.

3. 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 following 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 lb-ft).
^ Stage 2: Tighten to 55 Nm (41 lb-ft).





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





5. Tighten the 2 catalytic converter manifold bracket bolts.
^ Tighten to 20 Nm (15 lb-ft).
6. Install the 2 catalytic converter manifold shield bracket bolts and the bracket.
^ Tighten to 20 Nm (15 lb-ft).
7. Position the heat shield and install the 4 heat shield bolts.
^ Tighten to 10 Nm (89 lb-inch).
8. Install the 2 catalytic converter manifold-to-exhaust flexible pipe nuts.
^ Install a new gasket and nuts.
^ Tighten to 40 Nm (30 lb-ft).
9. Position the wiring harness bracket on the stud.
10. Connect the HO2S and 2 catalyst monitor sensor electrical connectors.
11. Install the generator air inlet duct.