Catalytic Converter: Service and Repair
Catalytic Converter ReplacementRemoval Procedure
Caution: Refer to Exhaust Service Cautions and Protective Goggles and Gloves, In Cautions and Notices.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Support the exhaust system near the resonator with a suitable jack.
3. Remove the oxygen sensor. It is not necessary to disconnect the electrical connector.
4. Remove the nuts securing the catalytic converter to the exhaust manifold pipe.
5. Remove the bolts securing the center exhaust hangers to the rear suspension support brackets.
6. Remove the catalytic converter from the manifold pipe.
7. Lower the exhaust system.
8. Remove the catalytic converter gasket. Do not reuse the gasket.
Important: Ensure the cut (2) is made on the catalytic converter side of the pipe.
9. Cut the catalytic converter (3) from the resonator inlet pipe (1) behind the step 2 but as close to the step as the tool will permit. The replacement catalytic converter will slide over the inlet pipe.
Installation Procedure
Important: Use care not to over extend the heated oxygen sensor pigtail.
1. Lower the exhaust system only enough to install the catalytic converter to the resonator inlet pipe (1).
Important: Ensure the solid portion of the catalytic converter heat shield is upward.
2. Slide two service clamps (2) over the catalytic converter outlet pipe (3). Do not tighten at this time. Slide the catalytic converter outlet pipe (3) over the resonator inlet pipe (1), until fully seated against the heated oxygen sensor boss.
Notice: Refer to Exhaust System Inspection in Cautions and Notices.
3. Place a NEW catalytic converter gasket over the catalytic converter studs.
Notice: Refer to Flex Decoupler Notice in Cautions and Notices.
4. Raise the exhaust system into position, aligning the catalytic converter with the exhaust manifold pipe.
5. Install the nuts securing the catalytic converter to the exhaust manifold pipe. Do not tighten at this time.
Notice: Refer to Fastener Notice in Cautions and Notices.
6. Install the bolts securing the center exhaust hangers to the rear suspension support brackets. Tighten the center exhaust hanger bolts to 30 N.m (22 lb ft).
7. Tighten the catalytic converter nuts. Tighten the catalytic converter nuts in a crisscross pattern to 25 N.m (18 lb ft).
8. Remove the jack from under the vehicle.
Important: Ensure the catalytic converter outlet pipe is fully seated against the heated oxygen sensor boss.
9. Position the service clamps midway on the catalytic converter outlet pipe, as close together as possible.
10. Rotate the clamps so the fastening ends are pointing in opposite directions. Tighten the service clamps to 30 N.m (22 lb ft).
11. Lower the vehicle.
12. Check the exhaust system for leaks.