Catalytic Converter: Service and Repair

Catalytic Converter Replacement (RPO LSJ)

Removal Procedure




1. Remove the heated oxygen sensor (HO2S) connector position assurance (CPA) retainer.
2. Disconnect the HO2S lead (2) from the engine harness electrical connector.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.




4. Bend the heat shield trough (2) down slightly until the HO2S lead (1) can be removed.




5. Remove the HO2S.




6. Remove the catalytic converter to muffler pipe nuts.
7. Pull the muffler pipe rearward and down until the studs are removed from the catalytic converter.




8. Remove the catalytic converter pipe to exhaust manifold nuts.
9. Remove the catalytic converter.
10. Remove and discard the exhaust gaskets.
11. Clean the flange mating surfaces of any remaining gasket material.

Installation Procedure




1. Install a NEW gasket onto the exhaust manifold studs.
2. Install the catalytic converter.

Notice: Refer to Fastener Notice.

3. Install the catalytic converter pipe to exhaust manifold nuts.

Tighten the nuts to 50 N.m (37 lb ft).




4. Install a NEW gasket onto the muffler pipe studs.
5. Pull the muffler pipe rearward and up until the studs are installed to the catalytic converter.
6. Remove the catalytic converter to muffler pipe nuts.

Tighten the nuts to 30 N.m (22 lb ft).




7. If reinstalling the old HO2S, coat the threads with anti-seize compound, Saturn P/N 21485279 or equivalent.
8. Install the HO2S.

Tighten the sensor to 42 N.m (31 lb ft).




9. Route the HO2S lead (1) through the heat shield trough (2), once done bend the trough until the HO2S lead is secured.
10. Lower the vehicle.




11. Connect the HO2S lead (2) to the engine harness electrical connector.
12. Install the HO2S CPA retainer.