Catalytic Converter - Installation

INSTALLATION





1. Install the converter to turbo seal ring (1).





2. Install the catalytic converter assembly (3).
3. Position the exhaust manifold shield and install the 3 bolts.
4. Tighten the shield bolts to 9 Nm (80 in. lbs.).

CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced.

5. install the catalytic converter v-clamp (2) at the turbocharger (1).
6. Tighten clamp to 8 Nm (71in. lbs).
7. Connect the O2 sensor connector.





8. Install the lower catalytic converter support bracket (2).
9. Install and tighten the bracket bolts (3) to 56 Nm (41 ft. lbs.).
10. Install a new converter to pipe gasket.
11. Install the front exhaust pipe.
12. Install the nuts that secure the cross under pipe to the catalytic converter.
13. Tighten the front exhaust pipe nuts to 56 Nm (41 ft. lbs.).





14. Install the front exhaust pipe support bolt (2). Tighten to 56 Nm (41 ft. lbs.).
15. Install the exhaust flange nuts (1). Tighten to 69 Nm (51 ft. lbs.).





16. Install the Charge Air Cooler (CAC) supply hose (5) to the turbocharger.
17. Install the CAC hose clamp and tighten.
18. Install the catalytic converter heat shield (3).





19. Tighten the nuts and bolts to 8 Nm (71 in. lbs.).
20. Connect the upstream and downstream O2 sensor connectors.





21. Install the air cleaner assembly (1).
22. Connect he fresh air intake hose (2).
23. Connect the two vacuum fittings (4), tighten the clamp (3) at the air to turbocharger inlet tube.
24. Connect the negative battery cable.