Buick Encore: Engine Heating and Cooling - Repair instructions

Exhaust front pipe replacement (LUV)

Removal Procedure

WARNING: Refer to Exhaust Service Warning .

WARNING: Refer to Protective Goggles and Glove Warning .

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the heated oxygen sensor - position 2 from the exhaust front pipe.

Fig. 1: Catalytic Converter And Exhaust Front Pipe

3. Remove the 2 fasteners (4) securing the warm up 3 way catalytic converter (3) to the exhaust front pipe (5).
4. Discard the exhaust front pipe gasket (2).

Fig. 2: Catalytic Converter

5. Remove the 3 fasteners (2) securing the exhaust front pipe (3) to the catalytic converter.
6. Discard the exhaust front pipe gasket (1).
7. Remove the exhaust front pipe (3).
8. If you are replacing the exhaust front pipe, transfer the heated oxygen sensor.

Installation Procedure

Fig. 3: Catalytic Converter

1. Install the exhaust front pipe (3) to the catalytic converter with a NEW gasket (1) and hand tighten the fasteners (2).

Fig. 4: Catalytic Converter And Exhaust Front Pipe

CAUTION: Refer to Flex Decoupler Caution .

CAUTION: Refer to Fastener Caution .

2. Install the exhaust front pipe (5) to the warm up 3 way catalytic converter (3) with a NEW gasket (2) and tighten the fasteners (4) to 17 (13 lb ft).

Fig. 5: Catalytic Converter

3. Tighten the exhaust front pipe fasteners (2) to 22 (16 lb ft).
4. Connect the heated oxygen sensor - position 2 to the engine wiring harness.
5. Start the engine and check for exhaust leaks.

EXHAUST FRONT PIPE REPLACEMENT

Removal Procedure

WARNING: Refer to Exhaust Service Warning .

WARNING: Refer to Protective Goggles and Glove Warning .

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Disconnect the heated oxygen sensor - position 2 harness connector.

Fig. 6: Muffler And Exhaust Pipe

NOTE: Do not twist or damage the flex coupling.

3. Remove the 2 fasteners (3) securing the exhaust muffler (4) to the exhaust front pipe (1).
4. Discard the exhaust front pipe gasket (2).

Fig. 7: Front Pipe Gasket And Fasteners

5. Remove the 3 fasteners (1) securing the exhaust front pipe (3) to the catalytic converter.
6. Discard the exhaust front pipe gasket (2).
7. Remove the exhaust front pipe (3).
8. If you are replacing the exhaust front pipe, transfer the heated oxygen sensor.

Installation Procedure

Fig. 8: Pipe Gasket And Fasteners

1. Install the exhaust front pipe (3) to the catalytic converter with a NEW gasket (2) and hand tighten the fasteners (1).

Fig. 9: Muffler And Exhaust Pipe

CAUTION: Refer to Fastener Caution .

NOTE: Do not twist or damage the flex coupler.

2. Install the exhaust front pipe (1) to the exhaust muffler (4) with a NEW gasket (2) and tighten the fasteners (3) to 17 (13 lb ft).

Fig. 10: Pipe Gasket And Fasteners

3. Tighten the exhaust front pipe fasteners (1) to 22 (16 lb ft).
4. Connect the heated oxygen sensor - position 2 to the engine wiring harness.
5. Start the engine and check for exhaust leaks.

CATALYTIC CONVERTER REPLACEMENT (2H0)

Fig. 11: Locating Catalytic Converter Components (1.8L LUW)

Catalytic Converter Replacement (2H0)

Catalytic converter replacement (LUV)

Removal Procedure

WARNING: Refer to Exhaust Service Warning .

WARNING: Refer to Protective Goggles and Glove Warning .

1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LUV).
2. Remove the catalytic converter heated oxygen sensor - 1. Refer to Heated Oxygen Sensor Replacement - Sensor 1 .
3. Remove the catalytic converter to the turbocharger clamp fastener and discard the clamp.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 12: Exhaust Front Pipe Fasteners & Gasket

5. Remove the exhaust front pipe fasteners (1) and discard the exhaust gasket (2).

Fig. 13: Catalytic Converter Brace & Fasteners

6. Remove the catalytic converter brace fasteners (1) from the catalytic converter brace (2).
7. Remove the catalytic converter.

Installation Procedure

Fig. 14: Catalytic Converter Brace & Fasteners

1. Install the catalytic converter into the catalytic converter brace (2) and loosely tighten the fasteners (1).

Fig. 15: Catalytic Converter V-Clamp

2. Install a NEW clamp into the position shown and loosely tighten the clamp fastener (1).

Fig. 16: Exhaust Front Pipe Fasteners & Gasket

CAUTION: Refer to Fastener Caution .

3. Install the exhaust front pipe (3) to the catalytic converter with a NEW gasket (2) and tighten the fasteners (1) to 22 N.m (16 lb ft).

Fig. 17: Catalytic Converter Brace & Fasteners

4. Tighten the catalytic converter brace fasteners (1) to 22 N.m (16 lb ft).
5. Lower the vehicle.
6. Tighten the turbocharge clamp fastener to 13 N.m (115 lb in).
7. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LUV).
8. Install the catalytic converter heated oxygen sensor - 1. Refer to Heated Oxygen Sensor Replacement - Sensor 1 .
9. Start the engine and check for exhaust leaks.

WARM UP THREE-WAY CATALYTIC CONVERTER REPLACEMENT (2H0, LUV)

Removal Procedure

WARNING: Refer to Exhaust Service Warning .

WARNING: Refer to Protective Goggles and Glove Warning

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 18: Exhaust Muffler And Warm Up 3 Way Catalytic Converter

2. Loosen the exhaust clamp fastener (4) and remove the exhaust muffler (2), from the warm up 3 way catalytic converter (1), and the exhaust isolator (3).
3. Support the exhaust muffler (2) with mechanics wire.

Fig. 19: Catalytic Converter And Exhaust Front Pipe

4. Remove the 2 fasteners (4) securing the warm up 3 way catalytic converter (3) to the exhaust front pipe (5).
5. Remove the warm up 3 way catalytic converter (3) from the exhaust isolators (1) and remove the warm up 3 way catalytic converter from the vehicle.
6.  Discard the exhaust front pipe gasket (2).

Installation Procedure

Fig. 20: Catalytic Converter And Exhaust Front Pipe

1. Install a NEW exhaust gasket (2) onto the exhaust front pipe (5).

CAUTION: Refer to Fastener Caution .

2. Install the warm up 3 way catalytic converter (3) into the exhaust isolators (1) and the onto the exhaust front pipe (5). Tighten the fasteners (4) to 17 (13 lb ft).

Fig. 21: Exhaust Muffler And Warm Up 3 Way Catalytic Converter

3. Install the exhaust muffler (2) into the exhaust isolator (3) and the warm up 3 way catalytic converter (1).

   Tighten the exhaust clamp fastener (4) to 50 (37 lb ft).

4. Lower the vehicle.
5. Start the engine and check for exhaust leaks.

Exhaust muffler replacement (LUV)

Fig. 22: Exhaust Muffler

Exhaust Muffler Replacement (LUV)

EXHAUST MUFFLER REPLACEMENT (2HO)

Fig. 23: Exhaust Muffler (2HO)

Exhaust Muffler Replacement (2HO)

CATALYTIC CONVERTER HEAT SHIELD REPLACEMENT (2H0)

Removal Procedure

WARNING: Refer to Exhaust Service Warning .

WARNING: Refer to Protective Goggles and Glove Warning .

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Disconnect the heated oxygen sensor wiring harness plug.
3. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement.
4.  Disconnect the air conditioning compressor hose from the air conditioning compressor assembly. Refer to Air Conditioning Compressor Hose Replacement (2H0) .
5. Disconnect the air conditioning condenser hose from the compressor assembly. Refer to Air Conditioning Condenser Hose Replacement (2H0) .

Fig. 24: Wiring Harness Bracket

6. Remove the wiring harness bracket fastener (2) and the wiring harness bracket (1).
7. Remove the 2 exhaust manifold heat shield fasteners (4).
8.  Remove the exhaust manifold heat shield (3).

Installation Procedure

Fig. 25: Wiring Harness Bracket

1. Install the exhaust manifold heat shield (3).

CAUTION: Refer to Fastener Caution .

2. Install the 2 exhaust manifold heat shield fasteners (4) and tighten to 8 N.m (71 lb in).
3. Install the wiring harness bracket (1) and the wiring harness bracket fastener (2) and tighten to 15 N.m (11 lb ft).
4. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement.
5. Connect the air conditioning compressor hose to the air conditioning compressor assembly. Refer to Air Conditioning Compressor Hose Replacement (2H0) .
6.  Connect the air conditioning condenser hose to the compressor assembly. Refer to Air Conditioning Condenser Hose Replacement (2H0) .
7. Connect the heated oxygen sensor wiring harness plug.
8.  Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection

CATALYTIC CONVERTER FRONT HEAT SHIELD REPLACEMENT

Fig. 26: Catalytic Converter Front Heat Shield

Catalytic Converter Front Heat Shield Replacement

EXHAUST CROSSOVER PIPE HEAT SHIELD REPLACEMENT

Fig. 27: Exhaust Crossover Pipe Heat Shield

Exhaust Crossover Pipe Heat Shield Replacement

EXHAUST MANIFOLD HEAT SHIELD REPLACEMENT (LUV)

Fig. 28: Exhaust Manifold Heat Shield (1.4L LUV)

Exhaust Manifold Heat Shield Replacement (LUV)

EXHAUST REAR MUFFLER HEAT SHIELD REPLACEMENT

Fig. 29: Exhaust Rear Muffler Heat Shield

Exhaust Rear Muffler Heat Shield Replacement

READ NEXT: