Catalytic Converter Manifold Removal And Installation

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CATALYTIC CONVERTER MANIFOLD REMOVAL AND INSTALLATION - HYBRID










Removal

1. Remove the exhaust flexible pipe. See - Exhaust Flexible Pipe Removal/Installation.

2. Remove the 2 catalytic converter bracket bolts.

3. Disconnect the heated oxygen sensor (HO2S) and the catalyst monitor sensor electrical connectors.






4. 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.

5. Remove and discard the 7 catalytic converter and exhaust manifold nuts.

6. Remove the catalytic converter and exhaust manifold from the vehicle.

- Discard the catalytic converter and exhaust manifold gasket.

7. Remove and discard the 7 catalytic converter and exhaust manifold studs.

8. Clean and inspect the catalytic converter and exhaust manifold. See - Testing and Inspection.

Installation

1. Install the 7 new catalytic converter and exhaust manifold studs.

- Tighten to 17 Nm (1.7 kgf-m, 13 ft-lbf).

2. Position a new catalytic converter and exhaust manifold gasket on the engine.







NOTE: Make sure to tighten the nuts in the sequence in 2 stages.

3. Position the catalytic converter and tighten the 7 exhaust manifold nuts in 2 stages in the sequence shown:

- Step 1: Tighten to 47 Nm (4.7 kgf-m, 35 ft-lbf).
- Step 2: Tighten to 47 Nm (4.7 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.






4. If installing a new converter, install the HO2S and the catalyst monitor sensor using the special tool.

- Tighten to 47 Nm (4.7 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. Install the 2 catalytic converter bracket bolts.

- Tighten to 25 Nm (2.5 kgf-m, 18 ft-lbf).

7. Install the flexible exhaust pipe. See - Exhaust Flexible Pipe Removal/Installation.