Catalytic Converter: Service and Repair

REMOVAL
1. Raise vehicle on hoist.
2. Remove rocker panel cover.
3. Apply penetrating oil to band clamps of component being removed.





4. The catalytic converter, resonator/intermediate pipe, and muffler are three separate components of the exhaust system.
5. Loosen and remove V-Band clamp at exhaust manifold flange. Discard V-Band clamp.

NOTE: Do not reuse V-Band clamp.

6. Remove exhaust pipe support isolator at front of converter.
7. Loosen band clamp at rear of converter.
8. Remove catalytic converter assembly.

NOTE: When replacement is required on any component of the exhaust system, it is important that original equipment parts be used for the following reasons:
^ Ensure proper alignment with other parts in the system
^ Provide acceptable exhaust noise levels
^ Does not change exhaust system back pressure that could affect emissions and performance

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 horoscope or equivalent. Remove oxygen sensor(s) and insert borescope. If horoscope 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
1. Install converter to resonator/intermediate pipe. Do not tighten band clamp at this time to permit alignment of all parts.
2. Install a NEW V-Band clamp at exhaust manifold to converter pipe connection.
3. Tighten V-Band clamp to 11 Nm (100 in. lbs.).
4. Starting from the front of exhaust system, align each component to maintain position and proper clearance with body parts.
5. Tighten exhaust pipe support to 28 Nm (250 in. lbs.).
6. Tighten band clamp to 70 Nm (55 ft. lbs.).
7. Install rocker panel cover.
8. Lower vehicle.