Catalytic Converter: Service and Repair

Component Notes And Information

NOTE:
^ During service procedures, refer to the illustration above and the information below.
^ After performing work on the exhaust system, ensure that the system is not under tension and that there is sufficient clearance to the body.
^ If necessary loosen clamps and mufflers and align exhaust pipes such that there is sufficient clearance to the body over the full length of the exhaust and the supports are uniformly loaded.
^ Replace self-locking nuts

Exhaust System Components, Removing And Installing

NOTE: Align exhaust system longitudinally to maintain dimension -a-.

1 Heat shield
- Removing: first remove pipe between EGR valve and exhaust manifold, refer to Powertrain Management
2 Exhaust manifold
- 2 piece
3 Lifting eye
4 Nuts and Bolts
- Tighten to:
M8: 25 Nm (18 ft lb)
M10: 40 Nm (30 ft lb)
- Always replace
5 Heat shield
- For Three-Way catalyst
6 4-pin harness connector
- Black
- Mounted to sub-frame
- For Oxygen sensor and Oxygen sensor heating
7 Bolt
- Tighten to: 10 Nm (7 ft lb)
8 Front exhaust pipe
9 Heated Oxygen sensor -G39-
- Tighten to: 50 Nm (37 ft lb)
- Only grease threads using "G5"; do not allow "G5" to enter the sensor slots
- Checking, refer to Computers and Control Systems.
10 Gasket
- Replace
11 Insulation rubber
- For front exhaust pipe (item 8)
12 Support bracket
- For insulation rubber
- Mounted to sub-frame
13 4-pin harness connector
- Brown
- For Oxygen sensor 2 and Oxygen sensor 2 heating after Three-Way catalyst
- Mounted to sub-frame
14 Heated Oxygen sensor 2 -G108-
- Tighten to: 50 Nm (37 ft lb)
- Installation location: in Three-Way catalyst
- Only grease threads using "G5"; do not allow "G5" to enter the sensor slots
15 Connection to front muffler
16 Three-Way Catalytic converter
17 Heat shield
18 Dimension -a-
- -a- = 10 mm minimum
19 Mounting
- Replace if damaged
- Note installed position
20 Connection
- Tighten to: 35 Nm (26 ft lb)
- For pipe between EGR valve and exhaust manifold
21 Connection to pipe
- For Exhaust gas outlet, refer to Replacement. Service and Repair