Catalytic Converter: Service and Repair

CATALYTIC CONVERTER - 2.0L/2.4L

REMOVAL

NOTE: In the following procedure it is not necessary to separate the muffler/pipe assembly from the resonator/pipe assembly. They can both be removed as an assembly.

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.

1. Raise vehicle on hoist and apply penetrating oil to resonator/pipe assembly band clamp, and the fasteners that connect the catalytic converter to the exhaust manifold.
2. Remove ground strap from muffler.
3. Loosen band clamp for resonator/pipe assembly.

CAUTION: Do not use any tools to remove the rubber isolators-remove by hand only. Soapy water or silicone-based lubricant spray may be used to assist removal/installation of isolators. DO NOT use a petroleum-based lubricant on the isolators, as damage to the rubber material can occur.

4. Remove support isolators from muffler supports.
5. Remove resonator/pipe and muffler/pipe as an assembly
6. Disconnect downstream oxygen sensor connector.
7. Remove fasteners that attach catalytic converter to the exhaust manifold. Remove catalytic converter from vehicle.
8. Remove and discard gasket.

INSPECTION

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.

Check catalytic converter for a flow restriction.
Visually inspect the catalytic converter element by using a bore scope or equivalent. Remove oxygen sensor(s) and insert bore scope. If bore scope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate.

NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. (Refer to Appropriate Diagnostic Information) for test procedures.

INSTALLATION

NOTE: Always work from the front to rear of exhaust system when aligning and tightening exhaust system components.

1. Clean manifold to converter sealing surfaces.
2. Position new gasket on exhaust manifold.

NOTE: If catalytic converter is being replaced, transfer downstream oxygen sensor to new converter.

3. Loosely attach catalytic converter to exhaust manifold.
4. Loosely install resonator/pipe and muffler/pipe assembly to catalytic converter outlet pipe.
5. Install support isolators to muffler supports.
6. Align exhaust system to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them. Tighten fasteners attaching catalytic converter to exhaust manifold to 28 Nm (250 inch lbs.).
7. Tighten resonator/pipe assembly band clamp to 54 Nm (40 ft. lbs.).
8. Connect ground strap to muffler.
9. Lower vehicle.