Catalytic Converter: Service and Repair

Catalytic Converter Replacement

Removal Procedure






1. Raise the vehicle.
2. Disconnect the heated oxygen sensor (HO2S) electrical connections from catalytic converter pipe.
3. Remove the exhaust hanger bolts and hanger from the transmission.
4. Remove the nuts and the seals retaining the catalytic converter pipe to the exhaust manifolds.

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.






5. Remove the flange nuts from the catalytic pipe to the muffler.
6. Remove the catalytic converter from the vehicle.
7. Remove the oxygen sensors as necessary. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Service and Repair.

Installation Procedure






1. Install the oxygen sensors as necessary. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Service and Repair.
2. Position the catalytic pipe to the vehicle.
3. Install the retaining nuts to the front of the muffler.
Do not tighten the nuts.

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 new seals, the nuts and the exhaust pipe flange to exhaust manifold.

Tighten
- Tighten the exhaust pipe flange to exhaust manifold nuts to 65 Nm (48 lb ft).
- Tighten the catalytic converter to muffler retaining nuts to 48 Nm (35 lb ft).






5. Connect the HO2S electrical connections.
6. Install the exhaust hanger and bolts to the transmission.

Tighten
Tighten the bolts to 17 Nm (13 lb ft).

Notice: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials.

7. Verify the exhaust system for proper clearance and the alignment of all components.
8. Lower the vehicle.