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 Air Injection (AIR) 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 (150 lb-in).

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

3. NOTICE: 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.

NOTICE: 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 AIR hose to the catalytic converter manifold.





5. Tighten the 2 catalytic converter manifold bracket bolts.
- Tighten to 20 Nm (177 lb-in).

6. Install the 2 catalytic converter manifold shield bracket bolts and the bracket.
- Tighten to 20 Nm (177 lb-in).

7. Position the heat shield and install the 4 heat shield bolts.
- Tighten to 10 Nm (89 lb-in).

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.