Catalytic Converter-2.0L PZEV

Removal and Installation





Material

1. Position the vehicle on a hoist.
2. Relieve the fuel system pressure.





3. Remove the 2 catalytic converter-to-muffler assembly flange nuts. Discard the nuts.
4. Disconnect the catalyst monitor and the Heated Oxygen Sensor (HO2S) electrical connectors.





5. Remove the 2 catalytic converter-to-engine bracket bolts.





6. Remove the support bracket bolts.
7. Remove the 2 lower heat shield bolts.





8. Remove and discard the lower 4 catalytic converter nuts.
9. Lower the vehicle.





10. Disconnect the upper HO2S electrical connector. Remove the wire harness from the retainer.





11. Disconnect the wiring connector, then remove the bolt and the bracket.





12. Remove the Vapor Management Valve (VMV) heat shield.





13. Disconnect the fuel lines then disconnect the VMV upper fuel line and the VMV lower fuel line.





14. Remove the VMV bolts. Position the VMV and bracket aside.





15. Remove the upper 3 catalytic converter nuts and studs. Discard the nuts.





16. Remove the PCV hose and the secondary air hose.





17. Remove the engine lifting eyelet.





18. Position the power steering reservoir aside.





19. Remove the catalytic converter.





20. NOTE: If installing a new converter, remove the catalyst monitor sensors.

Remove the HO2S and the catalyst monitor.











21. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensor before installation.

NOTE: Clean the mating surfaces of the exhaust manifold and the catalytic converter mating surfaces.

NOTE: Always install new fasteners and gaskets.

NOTE: Do not tighten the fasteners until all components are assembled. Make sure to tighten all fasteners beginning at the front of the vehicle.

To install, reverse the removal procedure.
- Using a straightedge and feeler gauge, place the straightedge across the catalytic converter flange surface and check for warpage with the feeler gauge. If the reading is greater than the maximum specification, install a new catalytic converter, gasket and nuts.
- Tighten the nuts to specification in the sequence shown.