Catalytic Converter: Service and Repair

Exhaust Connector Holder:

REMOVAL

NOTE: When servicing the catalyst and inlet pipe assembly it is necessary to take the following precautions to make sure that the exhaust system flex tube is not damaged in any way. The bellows of the exhaust system flex tube are extremely sensitive to large deflections. To make sure that the useful life of the bellows is achieved it needs to be supported using the Exhaust Connector Holder and not allowed to hang under its own weight when not attached to the muffler or inlet pipe catalyst assembly.

CAUTION: Whenever servicing the exhaust system and removing any fastener hardware between the engine and the muffler, be sure to disconnect the two upstream Heated Oxygen Sensors (HO2S) and the two downstream heated oxygen sensors to prevent the exhaust system from being suspended by the HO2S pigtail/harness and causing damage.

^ Raise the vehicle.
^ Install exhaust connector holder.
^ Remove catalyst inlet pipe assembly-to-flex coupling bolts, and gasket.
^ Unplug and remove HO2S sensors from catalyst inlet pipe assembly.

NOTE: Use of penetrating oil may help ease removal of exhaust nuts.

^ Remove inlet pipe flange-to-exhaust manifold nuts.
^ Remove catalyst bracket-to-transmission vertical bolt and horizontal nut.
^ Remove dual converter Y pipe assembly from engine.
^ Using a medium-grade sandpaper (150 grit), polish the spherical surface of the exhaust manifolds, removing all loose rust. This aids in obtaining a good seal between the exhaust manifold sphere and the inlet pipe flare.

INSTALLATION
^ Reverse procedure for installing dual converter Y pipe assembly.
^ Lower vehicle.