Catalytic Converter: Service and Repair
Catalytic ConverterMaterial:
Material
Removal and Installation
WARNING: The normal operating temperature of the exhaust system is very high. Never attempt to service any part of the system until it has cooled. Be especially careful when working around the three-way catalytic converter. The temperature of the three-way catalytic converter rises to a high level after only a few minutes of engine operation.
CAUTION: Do not use oil or grease-based lubricants on the isolators. They may cause deterioration to the rubber.
CAUTION: Oil or grease-based lubricants on the isolators may cause the exhaust hanger isolators to separate from the exhaust hanger bracket during vehicle operation.
NOTE: Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.
1. Remove the front exhaust manifold heat shield.
2. Remove and discard the front catalytic converter bolts.
^ To install, tighten to 40 Nm (30 ft. lbs.).
3. With the vehicle in NEUTRAL, position it on a hoist.
4. Position a jack stand to support the muffler and resonator assembly.
5. Remove and discard the underbody catalytic converter nuts and Y-pipe studs.
^ To install, tighten the nuts to 40 Nm (30 ft. lbs.).
6. NOTE: Inspect the isolator and install a new one if necessary.
Disconnect the resonator isolator.
7. Loosen the Torca (R) clamp.
^ To install. tighten to 47 Nm (35 ft. lbs.).
8. CAUTION: Do not strike the catalytic converter or subject it to any force impacts (i.e. hammer blows). Doing so will damage the catalyst material
Remove the under body catalytic converter and discard the gasket.
9. Loosen the Torca (R) clamp.
10. NOTE: Inspect the isolator and install a new one if necessary.
Disconnect the muffler front isolator.
11. NOTE: Inspect the isolator and install a new one if necessary.
Disconnect the muffler rear isolator.
12. Remove the muffler and resonator assembly.
13. Position a jack stand to support the Y-pipe assembly.
14. CAUTION: The catalytic converter nuts must be tightened as indicated to maintain correct exhaust system sealing and to prevent damage to the exhaust flanges.
Remove and discard the front catalytic converter nuts.
^ Alternately tighten the catalytic converter nuts while keeping the exhaust flanges parallel to one another. Tighten to 40 Nm (30 ft. lbs.).
15. CAUTION: The catalytic converter nuts must be tightened as indicated to maintain correct exhaust system sealing and to prevent damage to the exhaust flanges.
Remove and discard the rear catalytic converter nuts.
^ Alternately tighten the catalytic converter nuts while keeping the exhaust flanges parallel to one another. Tighten to 40 Nm (30 ft. lbs.).
16. NOTE: Inspect the isolator and install a new one if necessary.
Disconnect the Y-pipe isolator.
17. Disconnect the front catalyst monitor sensor electrical connector.
18. Remove the front catalytic converter bracket bolt.
^ To install, tighten to 40 Nm (30 ft. lbs.).
19. Remove the front catalytic converter and discard the upper gasket.
^ Inspect the catalytic converter bracket clamp. Install a new clamp, if necessary. Tighten the clamp bolt to 40 Nm (30 ft. lbs.).
20. NOTE: Apply anti-seize lubricant to the catalyst monitor sensor threads before installation.
If installing a new catalytic converter, remove the catalyst monitor.
^ To install, tighten to 47 Nm (35 ft. lbs.).
21. Disconnect the rear catalyst monitor sensor electrical connector.
22. Remove and discard the rear catalytic converter bolts.
^ To install, tighten to 40 Nm (30 ft. lbs.).
23. Remove the rear catalytic converter and discard the upper gasket.
24. NOTE: Apply anti-seize lubricant to the catalyst monitor sensor threads before installation.
If installing a new catalytic converter, remove the catalyst monitor.
^ To install, tighten to 47 Nm (35 ft. lbs.).
25. If necessary, remove the Y-pipe isolator bracket bolts, then remove the bracket.
^ To install, tighten to 30 Nm (22 ft. lbs.).
26. If necessary, remove the muffler rear isolator bracket bolts, then remove the bracket.
^ To install, tighten to 30 Nm (22 ft. lbs.).
27. NOTE: Clean the mating surfaces of the exhaust system connections.
To install, reverse the removal procedure.
^ Always install new gaskets and exhaust fasteners.