Catalytic Converter: Service and Repair

Catalytic Converter

Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air Induction.
3. Remove and discard the 2 catalytic converter-to-exhaust flexible pipe nuts.
^ Discard the gasket.
4. Remove the 4 bolts and the catalytic converter-to-engine bracket.
5. Remove the 3 bolts from the lower heat shield.

6. NOTE: It may be necessary to reposition the engine during catalytic converter removal.

Remove the roll restrictor bolt.
7. Disconnect the catalyst monitor sensor and heated oxygen sensor (HO2S) electrical connectors.
8. Remove the 6 bolts and the upper heat shield.
9. Remove the 2 retainers and the evaporative emission (EVAP) canister purge valve heat shield.
10. Disconnect the 2 vapor jumper tube-to-EVAP canister purge valve quick connect couplings and position them aside. For additional information, refer to Fuel Delivery and Air Induction.
11. Disconnect the fuel tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.
12. Disconnect the EVAP canister purge valve electrical connector.
13. Remove the 2 EVAP canister purge valve bracket bolts and position the EVAP canister purge valve and bracket assembly aside.
14. Remove and discard the 7 catalytic converter nuts.
15. Remove the bolt and the engine lifting eye.

16. NOTE: An assistant will be needed to remove the catalytic converter and lower heat shield from the vehicle. Do not let the catalytic converter or the lower heat shield come in contact with the valve cover.

Reposition the engine and carefully pull the catalytic converter and heat shield upward. Roll the heat shield toward the RH side of the vehicle and off of the catalytic converter.
^ Remove the catalytic converter from the vehicle.
^ Discard the gasket.
17. Remove and discard the 7 catalytic converter-to-cylinder head studs.
18. Clean and inspect the catalytic converter.

Installation
1. Install the 7 new catalytic converter-to-cylinder head studs.
^ Tighten to 17 Nm (13 lb-ft).
2. Position the new gasket on the engine.

3. NOTE: An assistant will be needed to install the catalytic converter and lower heat shield in the vehicle. Do not let the catalytic converter or the lower heat shield come in contact with the valve cover.

Reposition the engine and carefully lower the catalytic converter and heat shield downward. Roll the heat shield toward the LH side of the vehicle and onto the catalytic converter.
^ Using 7 new nuts, install the catalytic converter onto the engine.

4. CAUTION: Failure to tighten the catalytic converter manifold nuts to specification a second time will cause the converter to develop an exhaust leak.

Tighten the 7 new catalytic converter nuts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 55 Nm (41 lb-ft).
^ Stage 2: Tighten to 55 Nm (41 lb-ft).





5. Install the engine lifting eyelet and the bolt.
^ Tighten to 45 Nm (33 lb-ft).
6. Reposition the EVAP canister purge valve and bracket assembly and install the 2 bolts.
^ Tighten to 6 Nm (53 lb-in).
7. Connect the EVAP canister purge valve electrical connector.
8. Connect the 2 vapor jumper tube-to-EVAP canister purge valve and fuel tube quick connect couplings.
9. Install the EVAP canister purge valve heat shield and the 2 retainers.
10. Connect the HO2S and catalyst monitor electrical connectors.
11. Install the roll restrictor bolt.
^ Tighten to 70 Nm (52 lb-ft).
12. Position the lower heat shield and install the 3 bolts.
^ Tighten to 11 Nm (8 lb-ft).
13. Install the catalytic converter-to-engine bracket and install the 2 bolts.
^ Tighten to 47 Nm (35 lb-ft).
14. Install the 2 catalytic converter bracket-to-engine bracket bolts.
^ Tighten to 23 Nm (17 lb-ft).
15. Using a new gasket, install the 2 new catalytic converter-to-exhaust flexible pipe nuts.
^ Tighten to 47 Nm (35 lb-ft).
16. Install the upper heat shield and the 6 bolts.
^ Tighten to 11 Nm (8 lb-ft).