Catalytic Converter: Service and Repair

CATALYTIC CONVERTER

REMOVAL

CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.





1. Raise and support the vehicle.
2. Saturate all exhaust bolts and nuts with leopard Rust Penetrant. Allow 5 minutes for penetration.
3. Remove the clamp (3) holding the LH catalytic converter (4) to the RH catalytic converter (2).
4. If present, grind any tack welds.
5. Remove the catalytic converter-to-manifold bolts (1).
6. Remove the LH catalytic converter (4) from the RH catalytic converter (2).
7. Remove the clamp holding the RH catalytic converter (2) to the exhaust pipe(s).
8. If present, grind tack weld.
9. Remove the RH catalytic converter (2) from the extension pipe.
10. You may have to loosen up other sections of the exhaust system.

INSPECTION
Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose.

If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core.

INSTALLATION





1. Raise and support the vehicle.
2. Remove any burrs from the RH (2) and LH (4) catalytic converter.
3. Insert the RH (2) catalytic converter into the exhaust pipe.
4. Position the RH catalytic converter-to-exhaust pipe clamp. Do not tighten at this time.
5. Make sure the alignment tang is seated in the alignment slot.
6. Insert the LH catalytic converter 4) into the RH catalytic converter (2).
7. Make sure the alignment tang is seated in the alignment slot.
8. Position the LH catalytic converter-to-RH catalytic converter clamp (3). Do not tighten at this time.
9. Install the LH and RH catalytic converters (2 and 4) to the exhaust manifold. Tighten bolts to 34 Nm (24 ft. lbs.)
10. Connect the oxygen sensor electrical connectors.
11. Tighten exhaust clamps to 42 Nm (31 ft. lbs.).
12. If other sections of the exhaust system where loosened in removal, refer to that information for the tightening procedures.
13. Lower the vehicle.
14. Start the engine, inspect for exhaust leaks. Repair exhaust leaks as necessary.
15. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if necessary.