Catalytic Converter: Service and Repair
Catalytic Converter - 2.0L ZetecRemoval
1. Remove the heated oxygen sensor (HO2S).
2. Disconnect the exhaust gas recirculation (EGR) tube.
1 Remove the two bolts.
2 Loosen the EGR tube nut.
3. Remove the catalytic converter nuts.
^ Discard the nuts.
4. Remove the catalyst monitor sensor.
5. Remove the bolts and the catalytic converter bracket.
6. Remove the flagnuts and bolts.
^ Discard the flagnuts, springs and bolts.
7. Remove the catalytic converter bracket nuts.
8. Remove the catalytic converter and rear support bracket.
^ Discard the ring seal and gasket.
Installation
1. Position the catalytic converter into place and loosely install the two nuts.
^ Install new gasket and ring seal.
^ Install new nuts.
2. Connect the converter outlet to the muffler inlet pipe.
1 Position the rear support bracket and install the washers and nuts.
2 Loosely install the new bolts, springs and flagnuts.
3. Lower the vehicle.
4. Install the third catalytic converter nut and tighten all the nuts.
^ Install a new nut.
5. Connect the EGR tube and install the bracket bolts.
6. Raise the vehicle.
7. Tighten the converter outlet to the muffler inlet bolts.
8. Tighten the catalytic converter rear support bracket nuts.
9. Install the catalytic converter bracket and bolts.
10. Install the catalyst monitor sensor.
11. Install the HO2S.