Catalytic Converter and Exhaust Manifold

CATALYTIC CONVERTER AND EXHAUST MANIFOLD - 2.3L REMOVAL/INSTALLATION





Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the exhaust flexible pipe.
3. Remove the 2 catalytic converter bracket bolts.
4. Remove the 6 heat shield bolts and the heat shield.
5. Disconnect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.
6. Using the special tool, remove the HO2S and the catalytic monitor sensor.

Note
^ If installing a new converter, remove the heated oxygen sensor (HO2S) and the catalyst monitor sensor for installation in the new converter.





7. Remove and discard the 7 catalytic converter and exhaust manifold nuts.
8. Remove the catalytic converter and exhaust manifold from the vehicle.
^ Discard the catalytic converter and exhaust manifold gasket.
9. Remove and discard the 7 catalytic converter and exhaust manifold studs.
10. Clean and inspect the catalytic converter and exhaust manifold. See EXHAUST MANIFOLD - INSPECTION. Exhaust Manifold - Inspection

Installation
1. Install the 7 new catalytic converter and exhaust manifold studs.
^ Tighten to 17 N-m (1.7 kgf-m, 13 ft-lbf).
2. Position a new catalytic converter and exhaust manifold gasket on the engine.





3. Position the catalytic converter and exhaust manifold and tighten the 7 exhaust manifold and catalytic converter nuts in the sequence shown:
^ Step 1: Tighten to 47 N-m (4.8 kgf-m, 35 ft-lbf).
^ Step 2: Tighten to 47 N-m (4.8 kgf-m, 35 ft-lbf).

Caution
^ Failure to tighten the catalytic converter 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 nuts a second time will cause the converter to develop an exhaust leak.

Note
^ Make sure to tighten the nuts in the sequence in two stages.





4. If installing a new converter, install the HO2S and the catalyst monitor sensor using the special tool.
^ Tighten to 47 N-m (4.8 kgf-m, 35 ft-lbf).

Note
^ Apply anti-seize lubricant to the threads of the sensors before installation.

5. Connect the HO2S and the catalyst monitor sensor electrical connectors.
6. Position the heat shield and install the 6 heat shield bolts.
^ Tighten to 10 N-m (1.0 kgf-m, 89 in-lbf),
7. Install the 2 catalytic converter bracket bolts.
^ Tighten to 25 N-m (2.5 kgf-m, 18 ft-lbf).
8. Install the flexible exhaust pipe.