B2300 L4-2.3L VIN D (2004)
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For 2001-2003 models with an 1800-2200 RPM boom/vibration:
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Install the new muffler and exhaust pipe assembly and new front and rear hangers. Refer to 01-15A - EXHAUST SYSTEM 2.3L for removal
and installation procedures. Leave the catalytic converter pipe to muffler and exhaust pipe connection loose after installation. Torque the front
and rear hanger nuts to 23 N.m (17 lb-ft) and go to STEP 4.
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For 2004 models with an 1800-2200 RPM boom/vibration and for 2001-2004 models with a rough idle:
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Do not change the muffler and exhaust pipe. Loosen the nuts at the flange between the catalytic converter pipe and muffler and exhaust pipe
and go to STEP 4.
4.
Use the following procedure to neutralize the powertrain and exhaust system:
a.
Start the engine.
b.
Apply the park brake.
c.
Place the transmission in 1st gear.
d.
Slightly raise engine RPM and slowly let out clutch until Powertrain moves/shifts under torque.
e.
Place the transmission in reverse.
f.
Slightly raise engine RPM and slowly let out clutch until Powertrain moves/shifts under torque.
g.
Repeat this process again.
h.
Place transmission in Neutral and turn off engine.
5.
Torque the powertrain and exhaust system attachments to specification in the following sequence:
a.
Left engine insulator nuts - Tightening Torque: 102 N.m (75 lb-ft).
b.
Right engine insulator nuts - Tightening Torque: 102 N.m (75 lb-ft).
c.
Transmission extension housing-to-cross member mount nuts - Tightening Torque: 98 N.m (72 lb-ft).
d.
Exhaust manifold to catalytic converter pipe nuts (support the catalytic conveter and pipe in a neutral position while tightening) - Tightening
Torque: 40 N.m (30 lb-ft).
e.
Catalytic converter pipe-to-muffler and exhaust pipe nuts (do not support the exhaust pipe while tightening) - Tightening Torque: 40 N.m
(30 lb-ft).
NOTE:
Manual transmission models do not require an exhaust damper.
6.
Check the powertrain and exhaust to ensure there are no points grounded out to the body. Inspect for other possible ground-outs to the dash-panel,
like wire harness, hoses, etc.
7.
Start the engine and check for exhaust system leaks.
8.
Verify repair.
PCM REPROGRAMMING - 2003 AUTOMATIC TRANSMISSION MODELS ONLY
1.
Using WDS B25.6 or later software, reprogram the PCM to the latest calibration (refer to "Calibration Information" table) by following the
"Module Reprogramming" procedure.
NOTE:
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Always update the WDS PTU first, then install the needed calibration file that WDS shows during PCM reprogramming. Go to "WDS
Calibration" on ESI and download the "update" file. If the PTU is not updated to the latest WDS calibration level, the calibration file will
not install into the PTU.
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WDS shows the calibration part numbers afler programming the PCM.
