Catalytic Converter: Service and Repair

Catalytic Converter - 2.3L





Material

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





3. Remove the two catalytic converter-to-muffler assembly flange nuts. Discard the nuts.
4. Disconnect the catalyst monitor and the heated oxygen sensor (H02S) electrical connectors.





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





6. Remove the support bracket bolts.
7. Remove the two lower heat shield screws.





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





10. Disconnect the upper H02S electrical connector.





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








12. Disconnect the fuel lines.





13. Remove the two bolts and the fuel canister assembly.








14. Remove the vapor management valve (VMV).
1. Disconnect the VMV electrical connector.
2. Remove the upper fuel line.
3. Remove the lower fuel line.
4. Remove the two VMV bolts and the VMV.





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





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





17. Disconnect the heat shield from the bulkhead, then remove the heat shield.





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 H02S 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 a feeler gauge, place the straightedge across the catalytic converter flange surface and check for warping 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.