Catalytic Converter Removal/Installation

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CATALYTIC CONVERTER REMOVAL/INSTALLATION - HYBRID










Removal

1. Remove the exhaust crossover 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. Remove and discard the 7 catalytic converter manifold nuts.

5. Remove the catalytic converter from the vehicle.

- Discard the catalytic converter manifold gasket.

6. Remove and discard the 7 manifold studs.

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

Installation

1. Install the 7 new catalytic converter studs.

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

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






3. 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 to specification a second time will cause the converter to develop an exhaust leak.

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

4. 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).

1. Connect the HO2S and the catalyst monitor sensor electrical connectors.

2. Install the 2 catalytic converter bracket bolts.

- To install, tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.

3. Install the exhaust crossover pipe. See - Exhaust Flexible Pipe Removal/Installation.