Catalytic Converter Replacement

Catalytic Converter Replacement

Removal Procedure

Caution: Refer to Exhaust Service Caution and Protective Goggles and Gloves Caution in Service Precautions.





1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

2. Support the exhaust system near the resonator with a suitable jack.

3. Remove the oxygen sensor. It is not necessary to disconnect the electrical connector.

4. Remove the nuts securing the catalytic converter to the exhaust manifold pipe.





5. Remove the bolts securing the center exhaust hangers to the rear suspension support brackets.

6. Remove the catalytic converter from the manifold pipe.

7. Lower the exhaust system.

8. Remove the catalytic converter gasket. Do not reuse the gasket.


Important: Ensure the cut (2) is made on the catalytic converter side of the pipe.





9. Cut the catalylic converter (3) from the resonator inlet pipe (1) behind the step 2 but as close to the step as the tool will permit. The replacement catalytic converter will slide over the inlet pipe.



Installation Procedure

Important: Use care not to over extend the heated oxygen sensor pigtail.





1. Lower the exhaust system only enough to install the catalytic converter to the resonator inlet pipe (1).

Important: Ensure the solid portion of the catalytic converter heat shield is upward.

2. Slide two service clamps (2) over the catalytic converter outlet pipe (3). Do not tighten at this time. Slide the catalytic converter outlet pipe (3) over the resonator inlet pipe (1), until fully seated against the heated oxygen sensor boss.


Notice: Refer to Exhaust System Inspection Notice.





3. Place a NEW catalytic converter gasket over the catalytic converter studs.

Notice: Refer to Flex Decoupler Notice.

4. Raise the exhaust system into posilion, aligning the catalytic converter with the exhaust manifold pipe.

5. Install the nuts securing the catalytic converter to the exhaust manifold pipe. Do not tighten at this time.