Catalytic Converter: Service and Repair

REMOVAL

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.

1. Remove muffler and exhaust pipe.

Figure 11:

2. Disconnect downstream oxygen sensor (Fig. 11) electrical connector.

Figure 12:

Figure 13:

3. Remove catalytic converter to exhaust manifold attaching fasteners (Figs. 12 or 13).
4. Remove catalytic converter from vehicle. Remove and discard flange gasket (LEV only).

NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or equivalent) must be used.

INSTALLATION

NOTE: When assembling exhaust system, do not tighten clamps until all components are aligned and clearances are checked.

1. Assemble catalytic converter to exhaust manifold connection. Use a new flange gasket (LEV only).
2. Assemble muffler and exhaust pipe to catalytic converter. Install muffler and pipe support isolators to the underbody.

Figure 13:

3. Tighten the catalytic converter to exhaust manifold ball joint fasteners to 27 Nm (20 ft. lbs.) (Fig. 12) or flex joint attaching fasteners (LEV) to 28 Nm (250 inch lbs.) (Fig. 13).

Figure 14:

4. Working from the front of the system-align each component to maintain position and proper clearance with under body components (Fig. 14). Tighten all slip joint band clamps to 75 Nm (55 ft. lbs.).

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

5. If removed, install downstream oxygen sensor.
6. Connect downstream oxygen sensor electrical connector.