Catalytic Converter Removal and Installation
Precautions: General safety (00)
Removal
NOTICE:
Applying a shock to the catalytic converter may cause damage to the inside the catalyst.
Handle the catalytic converter carefully not to drop it or hit it against something.
1)Disconnect negative (–) cable at battery.
2)Drain coolant. 
3)Remove engine cover.
4)Remove air cleaner suction hose.
5)Remove clamp (1).
6)Disconnect HO2S-1 (1) and HO2S-2 (2) connectors and then detach from their bracket.
7)Remove HO2S-1 and HO2S-2, if necessary.
8)Remove turbocharger water inlet hose (3) and protector (4).
9)Remove turbocharger water inlet pipe.
10)Remove catalytic converter cover (1).
11)Remove exhaust No.1 pipe bolts (1) from catalytic converter.
12)Remove catalyst case stiffener (1).
13)Remove catalytic converter (2) and its gasket from turbocharger.
Installation
Reverse removal procedure noting the following points.
•Use new gaskets and seal ring.
•Use new catalyst case stiffener nut.
•Tighten turbocharger water inlet pipe union bolt to specified torque.
•Tighten bolts and nuts to specified torque.
•Install turbocharger water inlet hose (1) as it was and move protector (2) to cylinder side until cutout of the protector comes in contact with clamp (3).
•Fix each HO2S harness with clamp (1) at yellow mark.
•Install HO2S-1 and HO2S-2 if removed.
•Refill cooling system with coolant.
•Check cooling system for leakage.
•Run engine and check for exhaust gas leakage.
•Use new catalyst case stiffener nut.
•Tighten turbocharger water inlet pipe union bolt to specified torque.
•Tighten bolts and nuts to specified torque.
•Install turbocharger water inlet hose (1) as it was and move protector (2) to cylinder side until cutout of the protector comes in contact with clamp (3).
| “a”: | 1.5 mm (0.06 in.) | 2. | HO2S-2 harness |
•Refill cooling system with coolant.
•Check cooling system for leakage.
•Run engine and check for exhaust gas leakage.