Catalytic Converter - Non-PZEV Manifold

Catalytic Converter - 2.3L Manifold

Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the generator air inlet duct.





3. Remove the heated oxygen sensor (HO2S) and catalyst monitor sensor.
4. Remove the wiring harness bracket from the valve cover 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 6 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. Remove the 7 nuts and the catalytic converter manifold.
^ Discard the 7 nuts and the gasket.
10. Remove and discard the 7 catalytic converter manifold studs.
11. 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 sequence shown 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. Install the catalytic converter manifold shield bracket and the 2 bolts.
^ Tighten to 20 Nm (15 lb-ft).
5. Tighten the 2 catalytic converter manifold bracket bolts.
^ Tighten to 20 Nm (15 lb-ft).
6. Position the heat shield and install the 6 heat shield bolts.
^ Tighten to 10 Nm (89 lb-inch).
7. Install the 2 catalytic converter manifold-to-exhaust flexible pipe nuts.
^ Install a new gasket and nuts.
^ Tighten to 40 Nm (30 lb-ft).
8. Position the wiring harness bracket on the stud.
9. Install the HO2S and catalyst monitor sensors.
10. Install the generator air inlet duct.