Catalytic Converter: Service and Repair

Exhaust System w/Catalytic Converter:

1. Remove the two nuts and bolts securing the converter pipe assembly to the muffler/outlet pipe assembly. For long wheel base vehicles also remove the catalyst to rear engine mount U-bolt.
2. Remove the two bolts attaching the converter pipe assembly to the exhaust manifold.
3. Remove the converter pipe assembly from the vehicle.
4. Clean all mating surfaces.
5. Install the converter onto the exhaust manifold studs and loosely secure in place.
6. Install a new non-asbestos gasket between the converter pipe and muffler/outlet pipe assembly. Install the fasteners and torque them to 27-31 ft lb (36-42 Nm).
7. Position the U-bolt and bracket assembly so the rod is aligned throughout the entire length of the bracket and insulator assembly and the U-bolt saddle notch is on the converter keyway. While maintaining proper alignment, torque the nuts to 27-31 ft lb (36-42 Nm).
8. Alternately tighten the exhaust manifold flange to a final torque of 25-34 ft lb (34-46 Nm).