Manuals+

Walker 15828

Walker Ultra EPA 15828 Direct Fit Catalytic Converter Instruction Manual

For Ford Ranger and Mazda B2300 Vehicles

1. Introduction

This manual provides essential information for the proper installation, operation, and maintenance of your Walker Ultra EPA 15828 Direct Fit Catalytic Converter. This component is designed to meet EPA standards for OBDII vehicles, ensuring your exhaust system complies with legal emissions limits. It features a robust stainless-steel body for durability and consistent performance.

Walker Ultra EPA 15828 Direct Fit Catalytic Converter
Figure 1: The Walker Ultra EPA 15828 Direct Fit Catalytic Converter. This image displays the complete catalytic converter assembly, including the inlet and outlet pipes with flanges, and the main converter body.

2. Compatibility

The Walker Ultra EPA 15828 Catalytic Converter is specifically designed for direct-fit replacement in the following vehicles:

  • 1995-1997 Ford Ranger
  • 1995-1997 Mazda B2300

Before installation, verify compatibility using your vehicle's year, make, model, engine, and trim information. Consult your vehicle's service manual for specific exhaust system configurations.

3. Key Features

  • EPA Compliant: Designed for use on pre-OBDII vehicles (1995 and older) to meet federal emissions standards. Consult local regulations for specific state requirements.
  • Direct-Fit Design: Engineered for a bolt-on replacement, featuring OE-style hangers, brackets, routings, and heat shields. This design simplifies installation, eliminating the need for specialized fabrication or welding.
  • Assured Performance: Utilizes OE-style high-technology washcoat and optimal precious metal loading to achieve the necessary reduction in tailpipe emissions for the specified vehicle applications.
  • Durable Construction: Features thick OE-style flanges, hangers, and brackets for enhanced strength and longevity. Aluminized heat shields, where originally equipped, protect the vehicle's undercarriage from heat generated by the converter.
  • No Break-In Required: Ready for immediate operation upon installation due to application-specific converter shell design and mat compression.
No break-in required for catalytic converter
Figure 2: Illustration indicating that no break-in period is required for the catalytic converter. The image shows a close-up of the converter body with text emphasizing immediate operational readiness.

4. Installation Instructions

Installation of a catalytic converter requires specialized tools and automotive knowledge. It is highly recommended that this component be installed by a qualified automotive technician.

4.1 Pre-Installation Checks

  • Ensure the vehicle's exhaust system is cool before beginning work.
  • Inspect the new catalytic converter for any shipping damage.
  • Confirm all necessary gaskets, bolts, and spring kits are available. These are typically not included with the converter and must be purchased separately.

4.2 Removal of Old Converter

  1. Safely lift and support the vehicle.
  2. Locate the existing catalytic converter.
  3. Disconnect any oxygen sensors attached to the converter or adjacent pipes.
  4. Unbolt the flanges connecting the converter to the exhaust manifold and the rest of the exhaust system.
  5. Carefully remove the old converter assembly.

4.3 New Converter Installation

  1. Clean all mating surfaces on the exhaust manifold and connecting pipes.
  2. Install new gaskets at all connection points.
  3. Position the new Walker Ultra EPA 15828 converter into place, aligning the bolt holes.
  4. Secure the converter using new bolts, nuts, and spring kits. Tighten fasteners to manufacturer specifications.
  5. Reconnect any oxygen sensors, ensuring proper torque and electrical connections.
  6. Verify all connections are secure and free of leaks.
  7. Lower the vehicle.
Mechanic installing catalytic converter
Figure 3: A mechanic working underneath a vehicle, installing an exhaust component. This illustrates the professional installation process for the direct-fit catalytic converter, emphasizing the need for proper tools and expertise.
Close-up of catalytic converter flanges
Figure 4: A close-up view of the robust flanges on the catalytic converter. These flanges are designed for a secure, leak-free connection to the vehicle's exhaust system.

5. Operation and Emissions Compliance

The catalytic converter is a critical component of your vehicle's exhaust system, responsible for reducing harmful pollutants from engine emissions. It converts toxic gases and pollutants in exhaust gas into less toxic pollutants by catalyzing redox reactions.

This Walker Ultra EPA 15828 converter is designed to maintain optimal exhaust efficiency and ensure your vehicle meets EPA emissions standards for its applicable model years. Proper installation and a well-maintained engine are crucial for the converter's effective operation.

Catalytic converter designed to keep check engine light off
Figure 5: Image highlighting the catalytic converter's role in preventing the illumination of the check engine light. The text indicates that optimal washcoat technology helps manage emissions codes.

6. Maintenance

Catalytic converters generally require no routine maintenance. However, the longevity and efficiency of the converter are directly linked to the overall health of your engine and exhaust system. Regular vehicle maintenance, including timely oil changes, spark plug replacement, and addressing engine misfires, will help prevent premature converter failure.

  • Ensure your engine is running efficiently to prevent unburnt fuel from damaging the converter.
  • Periodically inspect the exhaust system for leaks, corrosion, or damage.
  • Address any engine warning lights promptly to prevent issues that could affect the catalytic converter.

7. Troubleshooting

If you experience issues after installing the catalytic converter, consider the following:

7.1 Check Engine Light (CEL)

If the Check Engine Light illuminates after installation, it may indicate an issue with the exhaust system or engine. Common causes related to catalytic converters include:

  • Oxygen Sensor Issues: Faulty or improperly installed oxygen sensors can trigger a CEL. Ensure sensors are correctly connected and functioning.
  • Exhaust Leaks: Leaks in the exhaust system, especially near oxygen sensors, can affect readings and trigger a CEL. Inspect all connections for tightness.
  • Engine Performance Issues: Underlying engine problems (e.g., misfires, rich/lean fuel mixture) can cause the converter to operate inefficiently or become damaged, leading to a CEL. Address engine issues first.

It is recommended to have the vehicle diagnosed by a professional technician using an OBD-II scanner to retrieve diagnostic trouble codes (DTCs) for accurate troubleshooting.

Check Engine Light on dashboard
Figure 6: A close-up of a vehicle dashboard showing the illuminated Check Engine Light. This light indicates a potential issue with the engine or emissions system that requires attention.

8. Product Specifications

SpecificationDetail
BrandWalker
Model Number15828
MaterialMetal
Item Weight15.15 Pounds
Outside Diameter2.5 Inches
Product Dimensions48 x 10 x 8 inches
UPC086387158282

9. Regulatory Information

This catalytic converter is EPA compliant for use on pre-OBDII vehicles, specifically those manufactured in 1995 and older. It is designed to meet federal emissions requirements.

Important Note: Regulations regarding aftermarket catalytic converters vary by state. It is the installer's responsibility to consult local and state regulations to ensure compliance before purchase and installation. This product may not be legal for sale or use in California, Colorado, New York, or other states that require CARB-compliant replacement converters for certain vehicle years.

CARB Compliant logo for Walker CalCat Converters
Figure 7: A graphic displaying the 'CARB Compliant' logo for Walker CalCat Converters. This image also provides text detailing the applicability for OBDII vehicles (1996 and newer) and non-OBD vehicles (1995 and older), and states where CARB compliance is required.
Comparison table for catalytic converter types and compliance
Figure 8: A comparison table outlining different types of catalytic converters (CalCat Direct-Fit, Universal, Ultra Direct-Fit, Ultra Universal) and their compliance status (CARB-compliant, EPA-compliant) and installation characteristics (Direct-Fit, Universal).

10. Support and Warranty

For technical assistance, product inquiries, or warranty information, please contact Walker customer support directly. Keep your purchase receipt and product model number (15828) readily available when contacting support.

Specific warranty terms and conditions are provided by the manufacturer at the time of purchase. Review your product documentation for details.

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