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Converter, Catalytic: Installation: Installation

WARNING: This page is about a different car, the 2015 Fiat 500. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Converter/Turbo Gasket Ring
GC0153789Courtesy of CHRYSLER GROUP, LLC
  1. Install the new  converter to turbo seal ring (1).
    Fig 2: Turbocharger, Catalytic Converter Clamp & Catalytic Converter Assembly
    GC0153788Courtesy of CHRYSLER GROUP, LLC
  2. Install the catalytic converter assembly (3).
  3. Position the exhaust manifold shield and install the 2 bolts and one new  nut.
  4. Tighten the shield bolts and nut to 9 N.m (80 in. lbs.).
    CAUTION:

    Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced.

  5. Install the catalytic converter v-clamp (2) at the turbocharger (1).
  6. Tighten clamp to 8 N.m (71in. lbs.).
  7. Connect the oxygen sensor connector.
    Fig 3: Catalytic Converter, Support Mount & Bolts
    GC0153601Courtesy of CHRYSLER GROUP, LLC
  8. Install the catalytic converter lower support bracket (2).
  9. Install and tighten the bracket bolts (3) to 56 N.m (41 ft. lbs.).
  10. Install a new converter to pipe gasket.
  11. Install the front exhaust pipe.
  12. Install the front exhaust pipe gasket. Install the front exhaust pipe nuts to the converter outlet.
  13. Tighten the front exhaust pipe nuts to 56 N.m (41 ft. lbs.).
    Fig 4: Front Exhaust Pipe Support Bolt & Flange Nuts
    GC0153120Courtesy of CHRYSLER GROUP, LLC
  14. Install the front exhaust pipe support bolt (2). Tighten to 56 N.m (41 ft. lbs.).
  15. Install the exhaust flange gasket and nuts (1). Tighten the nuts to 69 N.m (51 ft. lbs.).
    Fig 5: Charge Air Cooler Supply Hose, Heat Shield, Nuts & Bolts
    GC0153600Courtesy of CHRYSLER GROUP, LLC
  16. Install the Charge Air Cooler (CAC) supply hose (5) to the turbocharger.
  17. Install the CAC hose clamp and tighten.
  18. Install the catalytic converter heat shield (3).
    Fig 6: Upper Heat Shield Bolts & Nuts
    GC0153792Courtesy of CHRYSLER GROUP, LLC
  19. Tighten the nuts and bolts to 8 N.m (71 in. lbs.).

    Care must be taken when tightening the shield bolts. If torque value is not correct, noise will occur. 

  20. Connect the upstream and downstream oxygen sensor connectors.
    Fig 7: Air Cleaner Assembly, Intake Hose, Fittings & Clamp
    GC0153787Courtesy of CHRYSLER GROUP, LLC
  21. Install the air cleaner assembly (1).
  22. Connect he fresh air intake hose (2).
  23. Connect the two vacuum fittings (4), tighten the clamp (3) at the air to turbocharger inlet tube.
  24. Connect the negative battery cable.
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