Auxiliary Catalytic Converter Replacement 2.0L Diesel

Warning: Refer to Battery Disconnect Warning in the Preface section.




1. Disconnect the negative battery cable.
2. Remove the engine under cover.
3. Remove the exhaust manifold heat shield with the bolts.




Note: The nuts and the stud may unscrew as a unit because of the high temperature associated with the exhaust manifold, but they can be re-used as such.

4. Remove the pup converter upper flange-to-exhaust manifold retaining nuts.



5. Remove the pup converter-to-exhaust front pipe retaining nuts.
6. Remove the exhaust front pipe mounting bracket bolt and nut.
7. Remove the pup converter and the gasket.
8. Clean the sealing surfaces on the exhaust front pipe flange and the exhaust manifold.
9. Check the exhaust front pipe and the exhaust manifold for holes, damage, open seams or other deterioration which could permit exhaust fumes to seep into the passenger compartment.

Caution: Refer to Fastener Caution in the Preface section.




1. Install the pup converter upper flange nuts and the gasket to exhaust manifold and tighten to 40 N·m (30 lb ft).



2. Install the pup converter and the gasket to the exhaust front pipe flange and tighten.

•	The pup converter-to-exhaust front pipe retaining nuts to 40 N·m (30 lb ft).

•	The exhaust front pipe mounting bracket bolt and nut to 40 N·m (30 lb ft).




3. Install the exhaust manifold heat shield and tighten bolts to 15 N·m (11 lb ft).
4. Install the engine under cover.
5. Connect the negative battery cable.

Auxiliary Catalytic Converter Replacement 3.2L

Warning: Refer to Battery Disconnect Warning in the Preface section.




1. Disconnect the negative battery cable.
2. Remove the exhaust front pipe. Refer to Front Pipe Replacement.



3. Remove the bank 2 pup converter upper flange-to-bank 2 exhaust manifold retaining nuts, 3 places.

Note: The nuts and the stud may unscrew as a unit because of the high temperature associated with the exhaust manifold, but they can be reused as such.

4. Remove the bank 2 pup converter and gasket.



5. Remove the bank 1 pup converter upper flange-to-bank 1 exhaust manifold retaining nuts, 2 places.

Note: The nuts and the stud may unscrew as a unit because of the high temperature associated with the exhaust manifold, but they can be reused as such.

6. Remove the bank 1 pup converter and the gasket.
7. Clean the ceiling surfaces on the exhaust front pipe and both of the exhaust manifolds.
8. Check the exhaust front pipe and both of the exhaust manifolds for holes, damage, open seams or other deterioration which could permit exhaust fumes to seep into the passenger compartment.

Caution: Refer to Fastener Caution in the Preface section.




1. Install the gasket and the bank 2 pup converter upper flange-to-bank 2 exhaust manifold retaining nuts, 3 places. Tighten the bank 2 pup converter upper flange nuts to 40 N·m (30 lb ft).



2. Install the gasket and the bank 1 pup converter upper flange-to-bank 1 exhaust manifold retaining nuts, 2 places. Tighten the bank 2 pup converter upper flange nuts to 40 N·m (30 lb ft).



3. Install the exhaust front pipe and tighten to 40 N·m (30 lb ft). Refer to Front Pipe Replacement.