1. Introduction
This instruction manual provides essential information for the proper installation, operation, and maintenance of your Walker Ultra EPA 16394 Direct Fit Catalytic Converter with Integrated Exhaust Manifold. Please read this manual thoroughly before proceeding with any installation or service to ensure safe and effective use.
2. Safety Information
WARNING: This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. For more information, visit www.P65Warnings.ca.gov.
Automotive repair and installation should only be performed by qualified professionals. Improper installation can lead to vehicle damage, personal injury, or failure to meet emissions standards. Always wear appropriate personal protective equipment, including safety glasses and gloves, during installation.
3. Compatibility
The Walker Ultra EPA 16394 Direct Fit Catalytic Converter is compatible with the following vehicle models:
- 2004-2006 Lexus RX330
- 2004-2007 Toyota Highlander
- 2004-2006 Toyota Sienna
Before purchasing and installing, verify that this part is suitable for your specific vehicle by checking the year, make, model, engine, and trim. Consult your vehicle's service manual for detailed compatibility information.
4. Product Overview
The Walker Ultra EPA 16394 is a direct-fit catalytic converter with an integrated exhaust manifold, designed for optimal emissions reduction and performance. It features an OE-style high-technology washcoat and optimal precious metal load to ensure compliance with EPA emissions requirements. The unit is constructed with thick OE-style flanges and manifolds for enhanced strength and durability, and includes aluminized heat shields where originally equipped to protect the undercarriage from heat.
Image 4.1: Walker Ultra EPA 16394 Direct Fit Catalytic Converter with Integrated Exhaust Manifold.
Image 4.2: Internal structure of a catalytic converter, illustrating the honeycomb ceramic substrate and precious metal coating for emissions conversion.
5. Setup and Installation
This catalytic converter features a direct-fit design, meaning it is engineered for a bolt-off, bolt-on installation. The integrated manifold assemblies attach directly to the engine cylinder head and are designed to match all downstream connections, simplifying the replacement process. No break-in period is required for this unit.
Image 5.1: Professional installation of an exhaust system component.
Professional installation by a certified mechanic is highly recommended to ensure correct fitment and optimal performance, as well as to comply with all local and federal regulations.
Installation Overview Video
Video 5.1: Overview of a catalytic converter and manifold assembly, similar to the Walker Ultra 16394, highlighting its components and fitment for compatible Toyota/Lexus models.
Product Unboxing Video
Video 5.2: Unboxing and presentation of a catalytic converter, showing the product and included accessories.
6. Operating Principles
The catalytic converter is a crucial component of your vehicle's exhaust system, responsible for reducing harmful emissions. It converts toxic pollutants in exhaust gas into less toxic substances by catalyzing redox reactions. This unit's high-technology washcoat and optimal precious metal load efficiently reduce tailpipe emissions such as nitrogen oxides (NOx), carbon monoxide (CO), and unburnt hydrocarbons (HC).
7. Maintenance
The Walker Ultra EPA 16394 is designed for long-lasting performance and durability. Regular vehicle maintenance, including engine tune-ups and proper fuel system care, contributes to the longevity and efficiency of the catalytic converter. Inspect the exhaust system periodically for any signs of damage, leaks, or corrosion. Address any issues promptly to prevent potential damage to the converter.
8. Troubleshooting
If your vehicle's Check Engine Light illuminates after installation or during operation, it may indicate an issue with the emissions system. The Walker Ultra converter is designed to keep the Check Engine Light off for emissions codes (e.g., P0420/P0430) when functioning correctly.
Image 8.1: An illuminated Check Engine Light on a vehicle dashboard.
If the Check Engine Light appears, it is recommended to:
- Inspect the appearance and carrier of the catalytic converter.
- Inspect the oxygen sensors.
- Inspect the Electronic Fuel Injection (EFI) system.
- Inspect the entire exhaust system for leaks or damage.
Consult a qualified mechanic for diagnosis and repair if the issue persists.
9. Specifications
| Attribute | Value |
|---|---|
| Manufacturer | Walker Exhaust |
| Brand | Walker |
| Model | Ultra EPA Direct Fit Catalytic Converter with Integrated Exhaust Manifold |
| Item Weight | 11.33 pounds |
| Product Dimensions | 14 x 12.5 x 9 inches |
| Item Model Number | 16394 |
| Exterior | Machined |
| Manufacturer Part Number | 16394 |
| What's in the Box | Manifold Converter |
10. Environmental Compliance
This Walker Ultra catalytic converter is EPA compliant, meaning it is approved for use on OBDII vehicles (1996 and newer) in all states that follow federal emissions standards. It is important to consult your state's aftermarket converter regulations for specific details, as some states (e.g., California, Colorado, New York, Maine) have stricter requirements (CARB compliant) that this specific EPA-compliant unit may not meet.
Image 10.1: Comparison table for different types of catalytic converters and their compliance with EPA and CARB standards.
11. Warranty
This product typically includes a 25,000-mile emissions warranty and a 5-year, 50,000-mile structural warranty. For detailed warranty terms and conditions, please refer to the documentation included with your product or contact Walker customer support.
12. Support
For technical assistance, troubleshooting, or warranty claims, please contact Walker customer support. It is advisable to have your product model number and purchase information readily available. If you are unsure about any aspect of installation or repair, seek assistance from a qualified automotive technician.
About Walker Ultra Catalytic Converters
Video 12.1: An informational video providing details about Walker Ultra Catalytic Converters and their features.
