Service Procedure
A. Replace Front Catalytic Converter1. Raise the vehicle on a hoist.
2. Disconnect the front catalyst from the rear catalyst, (Figure 1). Save the seal ring for re-use.
3. Lower the vehicle.
4. Disconnect the oxygen sensor electrical connector.
5. Remove the front turbocharger heat shield.
6. Remove the oxygen sensor and gasket.
7. Remove the secondary air injection tube.
8. Remove the rear turbocharger heat shield.
9. Remove the nuts securing the front catalyst to the turbocharger.
10. Slide the catalyst and gasket off the studs and remove them from the vehicle. Save the gasket for re-use.
11. Using the original gasket, install the new front catalyst on the studs. Tighten the nuts to 44 ft. lbs. (60 N-m) torque.
12. Reinstall the rear turbocharger heat shield. Tighten the bolts to 7 ft.lbs. (9 N-m) torque.
13. Reinstall the secondary air injection tube.
14. Using the supplied gasket, reinstall the oxygen sensor. Tighten the bolts to 20 ft.lbs. (27 N-m) torque.
15. Reinstall the front turbocharger heat shield. Tighten the nuts to 10 ft.lbs. (14 N-m) torque.
16. Reconnect the oxygen sensor electrical connector.
17. Raise the vehicle on a hoist. Using the original seal ring, tighten the stud nuts connecting the front catalyst and rear catalyst to 26 ft.lbs. (35 N-m) torque.
18. Lower the vehicle.
B. Install Recall Completion Label
1. With a ball point pen, print your dealer code (5 digits) on the supplied Recall Completion Label.
2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label.
C. Complete Proof of Correction Form
1. Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner.