Catalytic Converter - 2.0L PZEV
Catalytic Converter - 2.0L PZEVSpecial Tool(s):
Material:
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel system pressure.
3. Remove and discard the 2 catalytic converter-to-flex pipe flange nuts.
4. NOTE: When installing the catalytic converter, install a new gasket.
Remove and discard the catalytic converter-to-flex pipe gasket.
5. Remove the 4 catalytic converter-to-engine bracket bolts and the bracket.
6. Remove and discard the lower 4 catalytic converter nuts and studs.
7. NOTE: It will be necessary to reposition the engine during catalytic converter removal and installation.
Remove the roll restrictor bolt.
8. Disconnect the heated oxygen sensor (HO2S) and catalyst monitor electrical connectors.
9. Release the pushpin and disconnect the HO2S electrical connector.
10. Remove the 2 pushpin retainers, the evaporative emission (EVAP) canister purge valve and bracket heat shield.
11. Disconnect the fuel tubes and the EVAP canister purge valve electrical connector.
12. Remove the EVAP canister purge valve bracket bolts and position the EVAP canister purge valve and bracket aside.
13. Remove and discard the upper 3 catalytic converter nuts and studs.
14. Disconnect the secondary air hose.
15. Remove the engine lifting eyelet bolt and the engine lifting eyelet.
16. Remove the valve cover.
^ Using shop towels, cover the cylinder head.
17. NOTE: An assistant will be needed to remove the exhaust manifold and catalytic converter assembly. Do not let the catalytic converter come in contact with the cylinder head.
Reposition the engine and carefully pull the exhaust manifold and catalytic converter assembly upward to remove from the vehicle.
^ Discard the gasket.
18. NOTE: If installing a new converter, remove the catalyst monitor sensor and the 2 HO2S.
Remove the HO2S and the catalyst monitor.
Installation
1. NOTE: If installing a new converter, install the catalyst monitor sensor and the 2 HO2S.
Install the 2 HO2S and the catalyst monitor.
^ Tighten to 47 Nm (35 ft. lbs.).
2. NOTE: An assistant will be needed to install the exhaust manifold and catalytic converter assembly. Do not let the catalytic converter come in contact with the cylinder head.
Reposition the engine and carefully lower the exhaust manifold and catalytic converter assembly into position.
3. 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.
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 0.76 mm (0.0295 inch), install a new catalytic converter, gasket and nuts.
^ Install the new gasket and tighten the 7 new nuts and studs to 55 Nm (41 ft. lbs.) in the sequence shown.
4. Install the valve cover.
5. Install the engine lifting eyelet and the engine lifting eyelet bolt.
^ Tighten to 45 Nm (33 ft. lbs.).
6. Connect the secondary air hose.
7. Reposition the EVAP canister purge valve and bracket and install the bolts.
^ Tighten to 6 Nm (53 inch lbs.).
8. Connect the fuel tubes and the EVAP canister purge valve electrical connector.
9. Install the EVAP canister purge valve heat shield and the 2 pushpin retainers.
10. Connect the HO2S electrical connector.
11. Connect the HO2S and catalyst monitor electrical connectors.
12. Install the roll restrictor bolt.
^ Tighten to 48 Nm (35 ft. lbs.).
13. Install the 4 catalytic converter-to-engine bracket and the bolts.
^ Tighten to 47 Nm (35 ft. lbs.).
14. NOTE: When installing the catalytic converter, install a new gasket.
Install the new catalytic converter-to-flex pipe gasket.
15. Install the 2 new catalytic converter-to-flex pipe flange nuts.
^ Tighten to 47 Nm (35 ft. lbs.).