| Removal and Installation Special Tool(s) | | Alignment Pins, Subframe 205-316 (15-097A) | | | Separator, Ball Joint 211-020 (13-006) | General Equipment Transmission jack Securing strap CAUTION:Make sure the strut and spring assembly does not move in a forwards or rearwards direction, to prevent damage to the top mount center cup. | | -
NOTE:Make sure the road wheels are in the straight ahead position. Centralize the steering wheel and lock it in position. | | | -
Detach the steering column shaft from the steering gear pinion. - Discard the retaining bolt.
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Remove the cowl panel grille.
For additional information, refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
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Remove the bulkhead extension panel. - Remove the retaining screws and washers.
- Detach the panel from the retaining clips.
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Disconnect the heated oxygen sensor (HO2S) and catalytic monitor sensor electrical connectors. | 6. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Catalytic converter heat shield retaining bolts 2 - Catalytic converter heat shield 3 - Heated oxygen sensor (HO2S) 4 - Exhaust manifold retaining nuts and bolt 10 - Engine support insulator center retaining bolt 7. Install the components in the order indicated in the following illustration(s) and table(s). 7 - Engine support insulator center retaining bolt 13 - Catalytic monitor sensor 14 - Heated oxygen sensor (HO2S) 16 - Catalytic converter heat shield retaining bolts | | -
Connect the HO2S and catalytic monitor sensor electrical connectors. | | | -
Install the bulkhead extension panel. - Attach the panel to the retaining clips.
- Install the retaining screws and washers.
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Install the cowl panel grille.
For additional information, refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
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WARNING:Install a new steering column to steering gear pinion bolt. Failure to follow this instruction may result in personal injury. NOTE:Make sure the road wheels are in the straight ahead position. Attach the steering column shaft to the steering gear pinion. - Install a new retaining bolt.
| Removal Details Item 5 : Catalytic monitor sensor | | -
Raise and support the vehicle.
For additional information, refer to: Jacking (100-02 Jacking and Lifting, Description and Operation) /
Lifting (100-02 Jacking and Lifting, Description and Operation).
| Item 6 : Catalytic converter to muffler and tailpipe assembly retaining nuts | | -
Remove the floor panel brace. | | | -
CAUTION:Over bending of the exhaust flexible pipe may cause damage resulting in failure. Support the exhaust flexible pipe with a suitable support wrap or suitable splint. | | | -
CAUTION:Support the muffler and tailpipe assembly with suitable cable ties. Detach the exhaust flexible pipe from the muffler and tailpipe assembly. - Discard the gasket and nuts.
| Item 7 : Exhaust hanger insulators CAUTION:Take care when removing the exhaust hanger insulators to prevent damage. Item 8 : Tie-rod end | | -
Remove both front wheels and tires.
For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
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CAUTION:Leave the tie-rod end retaining nut in place to protect the ball joint stud. NOTE:Use a 5 mm Allen key to prevent the ball joint stud from rotating. Loosen the tie-rod end nut on both sides. | | | -
CAUTION:Protect the ball joint seal using a soft cloth to prevent damage. Using the special tool, detach the tie-rod end from the wheel knuckle on both sides. - Release the tie-rod end.
- Remove and discard the tie-rod end retaining nut.
| Item 9 : Stabilizer bar link | | -
NOTE:Use a 5 mm Allen key to prevent the ball joint stud from rotating. Detach the stabilizer bar link from the stabilizer bar on both sides. | Item 11 : Front axle crossmember | | -
Detach the headlamp leveling front sensor bracket from the right-hand lower arm and secure it to one side (if equipped). | | | -
Remove the right-hand front fender splash shield. | | | -
Detach the power steering fluid lines front bracket from the vehicle body. | | | -
Detach the power steering fluid lines center bracket from the vehicle body. | | | -
Using a suitable transmission jack and a wooden block, support the front axle crossmember, stabilizer bar and lower arm assembly. | | | -
WARNING:Make sure the front axle crossmember is secured to the transmission jack. Failure to follow this instruction may result in personal injury. | | | -
Remove the front axle crossmember bracket retaining bolts on both sides. | | | -
Remove the front axle crossmember retaining bolts (transmission jack removed for clarity). | | | -
CAUTION:To prevent damage to the power steering lines, only lower the front axle crossmember sufficiently to allow the catalytic converter to be removed. Lower the front axle crossmember. | Item 12 : Catalytic converter | | -
Remove the catalytic converter to catalytic converter support bracket retaining bolts. | | | -
With the aid of another technician, remove the catalytic converter. | Installation Details Item 2 : Exhaust manifold retaining nuts and bolt | | -
CAUTION:Never use jointing compound forward of the catalytic converter. NOTE:Coat the catalytic converter studs with grease. NOTE:Install a new gasket, nuts and bolt. NOTE:Do not fully tighten the exhaust manifold retaining nuts and bolt at this stage. Install the exhaust manifold retaining nuts and bolt. | Item 3 : Catalytic converter support bracket retaining bolts | | -
NOTE: Do not fully tighten the catalytic converter support bracket retaining bolts at this stage. Install the catalytic converter support bracket retaining bolts. | Item 4 : Exhaust hanger insulators | | -
CAUTION:Take care when installing the exhaust hanger insulators to prevent damage. Check the exhaust hanger insulators for damage. Install new exhaust hanger insulators as required. | Item 5 : Catalytic converter to muffler and tailpipe assembly retaining nuts | | -
NOTE:Coat the catalytic converter studs with anti-seize grease. NOTE:Install a new gasket and nuts. NOTE:Do not fully tighten the exhaust flexible pipe to muffler and tailpipe assembly retaining bolts at this stage. Install the exhaust flexible pipe to muffler and tailpipe assembly retaining bolts. | Item 6 : Front axle crossmember | | -
WARNING:Make sure the front axle crossmember is secured to the transmission jack. Failure to follow this instruction may result in personal injury. Using the transmission jack and the special tool, position and align the front axle crossmember. - Insert the alignment pins through the front axle crossmember alignment holes.
- Slide the locking plates into the groove of the special tool and tighten the alignment pin sleeve.
- Raise the front axle crossmember engaging the alignment pins into the chassis aligning holes.
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CAUTION:Make sure the front axle crossmember does not move while tightening the front axle crossmember retaining bolts. Install the front axle crossmember retaining bolts (transmission jack shown removed for clarity). | | | -
Install the front axle crossmember bracket retaining bolts on both sides. | | | -
Attach the power steering fluid lines center bracket to the vehicle body. | | | -
Attach the power steering fluid lines front bracket to the vehicle body. | | | -
Install the right-hand front fender splash shield. | | | -
Attach the headlamp leveling front sensor bracket to the right-hand lower arm (if equipped). | Item 8 : Tie-rod end | | -
NOTE:Install new tie-rod end retaining nuts. NOTE:Use a 5 mm Allen key to prevent the ball joint stud from rotating. Attach the tie-rod end to the wheel knuckle on both sides. | Item 9 : Stabilizer bar link | | -
NOTE:Use a 5 mm Allen key to prevent the ball joint stud from rotating. Attach the stabilizer bar link to the stabilizer bar on both sides. | Item 10 : Exhaust manifold retaining nuts and bolt | | -
Lower the vehicle to gain access to the exhaust manifold retaining nuts and bolt. | | | -
Tighten the exhaust manifold retaining nuts and bolt. | | | -
Raise and support the vehicle. For additional information, refer to: Jacking (100-02 Jacking and Lifting, DESCRIPTION AND OPERATION)/ Lifting (100-02 Jacking and Lifting, DESCRIPTION AND OPERATION). | Item 11 : Catalytic converter support bracket retaining bolts | | -
Tighten the catalytic converter to catalytic converter support bracket retaining bolts. | Item 12 : Catalytic converter to muffler and tailpipe assembly retaining nuts | | -
Tighten the catalytic converter to muffler and tailpipe assembly retaining nuts. | | | -
Install the floor panel brace. | Item 15 : Catalytic converter heat shield | | -
Feed the H2OS wiring harness and the catalytic monitor sensor electrical wiring harness through the heat shield. | |
