Catalytic Converter: Service and Repair

Catalytic Converter Replacement

1. Raise and support the vehicle.
2. Remove the post catalytic converter heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor 2 Replacement Service and Repair.






2. Remove the catalytic converter pipe-to-exhaust manifold nuts.
3. Carefully separate the converter pipe from the exhaust manifold.
4. Lower the converter pipe to rest on the rear crossmember of the front suspension frame.






5. Remove the catalytic converter pipe-to-exhaust extension pipe nuts.
6. Position the converter pipe forward and support the pipe.
7. Move the extension pipe rearward and down in order to separate the pipes.
8. Remove the catalytic converter pipe assembly from the vehicle.
9. If the exhaust gaskets have remained on the vehicle, remove the gaskets from the exhaust manifold and from the exhaust extension pipe, and discard the gaskets.
10. Clean the flange surfaces of any remaining gasket material.

Installation Procedure






1. Install NEW exhaust gaskets to the exhaust manifold and to the exhaust extension pipe. The gaskets are designed to be retained to the flange by the flange studs.
2. Position the catalytic converter pipe assembly to the vehicle.
3. Move the extension pipe rearward and down in order to connect the converter pipe to the extension pipe.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the catalytic converter pipe-to-exhaust extension pipe nuts.

Tighten
Tighten the nuts to 30 Nm (22 lb ft).

5. Carefully install the converter pipe to the exhaust manifold.






6. Install the catalytic converter pipe-to-exhaust manifold nuts.

Tighten
Tighten the nuts to 50 Nm (37 lb ft).

7. Install the post catalytic converter HO2S. Refer to Heated Oxygen Sensor 2 Replacement Service and Repair.
8. Lower the vehicle.