Catalytic Converter: Service and Repair

Catalytic Converter Replacement

Removal Procedure

Caution: Refer to Protective Goggles and Gloves Notice.

Notice: Refer to Vehicle Lifting.

Notice: Refer to OEM Standard Notice in Service Precautions.





1. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
2. Remove the transmission support. Refer to Transmission Support Replacement (RWD) or Transmission Support Replacement (4WD, ZR2).
3. Disconnect the LH pre-converter heated oxygen sensor (H02S) electrical connection.





4. Disconnect the RH pre-converter heated oxygen sensor (H02S) electrical connection.





5. Disconnect the post-converter heated oxygen sensor (H02S) electrical connection.





6. Remove the muffler to the catalytic converter flange nuts.
7. Remove the muffler from the catalytic converter.





8. Remove the catalytic converter to exhaust manifold flange nuts.





9. Remove the catalytic converter from the rubber catalytic converter hangers.
10. Remove the catalytic converter and gaskets from the vehicle.
11. Remove the heated oxygen sensors (HO2S) as necessary.

Installation Procedure





1. Install the heated oxygen sensors (H02S) as necessary.
2. Install the catalytic converter and NEW gaskets to the vehicle.
3. Install the catalytic converter to the catalytic converter rubber hangers.

Notice: Refer to Fastener Notice in Service Precaution.





4. Install the catalytic converter to exhaust manifold flange nuts.
^ Tighten the catalytic converter to exhaust manifold nuts to 53 Nm (39 ft. lbs.).





5. Install the muffler and NEW gasket to the catalytic converter.
6. Install the muffler to the catalytic converter flange nuts.
^ Tighten the muffler to the catalytic converter flange nuts to 40 Nm (30 ft. lbs.).





7. Connect the post-converter heated oxygen sensor (H02S) electrical connection.





8. Connect the RH pre-converter heated oxygen sensor (H02S) electrical connection.





9. Connect the LH pre-converter heated oxygen sensor (H02S) electrical connection.
10. Install the transmission support. Refer to Transmission Support Replacement (RWD) or Transmission Support Replacement (4WD, ZR2).
11. Lower the vehicle.