Catalytic Converter Manifold Removal/Installation

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CATALYTIC CONVERTER MANIFOLD REMOVAL/INSTALLATION - HYBRID










Removal

1. With the vehicle in NEUTRAL, position it on a hoist. See Lifting.

2. Remove the exhaust intermediate pipe. See - Service and Repair.

3. Remove the 2 exhaust bracket bolts.

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

5. Remove and discard the 7 catalytic converter 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, 150 in-lbf}.






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

- Stage 1: Tighten to 47 Nm {4.7 kgf-m, 35 ft-lbf}.
- Stage 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.
3. Connect the HO2S and the catalyst monitor sensor electrical connectors.

4. Install the 2 exhaust bracket bolts.

- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.

5. Install the intermediate exhaust pipe. See - Service and Repair.