Removal

REMOVAL

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.

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 the appropriate service diagnostic information for repair procedures.




1. Loosen intermediate pipe to catalytic converter clamp.

NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water.

2. Disconnect downstream oxygen sensor electrical connector.
3. Remove muffler/intermediate pipe isolators as necessary to slide muffle/intermediate pipe assembly out of catalytic converter.




4. Remove catalytic converter (3) to exhaust manifold attaching fasteners and remove converter from vehicle, 1.6L engine.




5. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle, 2.0L engine.




6. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle, 2.4L engine.




7. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle, 2.4L turbo engine.
8. Remove and discard flange gasket.

NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or equivalent) must be used.