Catalytic Converter: Service and Repair

Catalytic Converter

Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Using a jack stand, support the muffler.
3. Loosen the Torca coupler and disconnect the muffler inlet pipe from the catalytic converter assembly. Discard the Torca coupler.





4. CAUTION: When repairing the exhaust system or removing exhaust components, disconnect all Heated Oxygen Sensors (HO2S) and catalyst monitor sensors at the wiring connectors to prevent damage to the sensors and wiring harnesses.

Disconnect the RH and LH HO2S electrical connectors.





5. Disconnect the RH and LH catalyst monitor sensor electrical connectors.





6. Remove and discard the 2 RH catalytic converter to exhaust manifold nuts.
^ To install, tighten to 40 Nm (30 ft. lbs.).
^ Alternately tighten, in 10 Nm (89 inch lbs.) increments, the RH catalytic converter to exhaust manifold nuts to specification.





7. Remove and discard the 2 LH catalytic converter to exhaust manifold nuts.
^ To install, tighten to 40 Nm (30 ft. lbs.).
^ Alternately tighten, in 10 Nm (89 inch lbs.) increments, the LH catalytic converter to exhaust manifold nuts to specification.





8. NOTE: Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.

Remove the catalytic converter assembly.

9. NOTE: Using a Scotch Writer pad, clean the mating surfaces of the manifold outlet flare, the catalytic converter inlet flare, at the catalytic converter outlet flare and the muffler inlet pipe. Keep foreign materials out of the catalytic converters.

NOTE: Support the catalytic converter near the rear outlet while positioning the converter into place. Align the manifold studs into the pipe flange. Make sure not to damage the studs or mating surfaces.

^ Make sure to correctly align the catalytic converter to the exhaust manifold before installing the fasteners.

To install, reverse the removal procedure.
^ Always install new converter to manifold nuts and Torca coupler.