Front Catalytic Converter Replacement

FRONT CATALYTIC CONVERTER REPLACEMENT

WARNING: These procedures must be performed on a cool vehicle. Serious burns can result from a hot catalytic converter.





1. Remove the rear catalytic converter connection from the front catalytic converter (Figure 1).

Note: Spray lubricant onto bolts and/or nuts. If the bolts/nuts are difficuft to remove, alternately tighten and loosen them until they are free. DO NOT FORCE THE BOLTS/NUTS LOOSE!





2. Remove the upper heat protector (Figure 2).





3. Disconnect the oxygen sensor connector. Remove the oxygen sensor from the front catalytic converter (Figure 3). Carefully scrape away any gasket material from the oxygen sensor.

NOTE: Do not damage the oxygen sensor element when scraping away the old gasket.





4. Spray penetrating oil on the secondary air pipe threads. Carefully remove the secondary air pipe from the front catalytic converter (Figure 4).





5. Remove the remaining heat protectors from the front catalytic converter (Figure 5).





6. Remove the front catalytic converter and the catalytic converter to turbocharger outlet gasket (Figure 6).

Note: The catalytic converter to turbocharger outlet gasket should be reused if undamaged. Carefully inspect the gasket for damage. Replace the gasket if there is ANY damage.


FRONT CATALYTIC CONVERTER INSTALLATION

Install the new front catalytic converter from the emissions kit reversing the removal procedures.


STANDARD TORQUE VALUES

Catalytic converter to turbocharger - 50-70 N-m (37-50 ft.lbs.).

Heat protector screws - 8-10 N-m (6-7 ft.lbs.).

Oxygen sensor bolts - 25-30 N-m (18-22 ft.lbs.).

Rear catalytic converter flange nuts - 30-40 N-m (22-29 ft.lbs.).