Catalytic Converter: Service and Repair

Catalytic Converter Replacement

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Remove the transmission crossmember. Refer to Crossmember Replacement (Lower Control Arm) (Crossmember Replacement (Lower Control Arm)).




3. If replacing the three way catalytic converter remove the heated oxygen (HO2S) sensors (1 - 5) otherwise disconnect the heated oxygen (HO2S) sensors harness connectors. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (Heated Oxygen Sensor Replacement - Bank 1 Sensor 1) , Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Heated Oxygen Sensor Replacement - Bank 1 Sensor 2) , Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (Heated Oxygen Sensor Replacement - Bank 2 Sensor 1) and Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Heated Oxygen Sensor Replacement - Bank 2 Sensor 2).




4. Remove the catalytic converter pipe to the exhaust manifold nuts (1).
5. Remove the exhaust seals (2 and 3) and discard.




6. Loosen the band clamp bolt (1).
7. Remove the catalytic converter pipe from the vehicle.

Installation Procedure




1. Install NEW exhaust manifold seals (2 and 3).
2. Install the catalytic converter pipe to the exhaust manifolds.

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the catalytic converter pipe to exhaust manifold nuts (1) and tighten to 50 Nm (37 lb ft).




4. Position the three way converter to the muffler assembly and tighten the clamp bolt (1) to 44 Nm(32 lb ft).
5. Install the transmission crossmember. Refer to Crossmember Replacement (Lower Control Arm) (Crossmember Replacement (Lower Control Arm)).

Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from as exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.





6. If replacing the three way catalytic converter Install the heated oxygen (HO2S) sensors (1 - 5) otherwise Connect the heated oxygen (HO2S) sensors harness connectors. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (Heated Oxygen Sensor Replacement - Bank 1 Sensor 1) , Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (Heated Oxygen Sensor Replacement - Bank 1 Sensor 2) , Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (Heated Oxygen Sensor Replacement - Bank 2 Sensor 1) and Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (Heated Oxygen Sensor Replacement - Bank 2 Sensor 2).
7. Lower the vehicle.
8. Inspect for exhaust leaks.