Catalytic Converter: Service and Repair

REMOVAL

WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to service any part of the exhaust system until it has cooled. Use special care when working around the Three Way Catalytic Converter (TWC). These units heat to a high temperature after only a short period of engine operation.

1. Raise vehicle.
2. Remove retaining nuts from outlet flange on three way catalytic converter and remove the outlet gasket from the converter.
3. Remove Exhaust Gas Recirculation (EGR) valve to exhaust manifold tube, retaining bracket and clamp from the converter. Lower vehicle and remove heat shield and converter retaining nuts from exhaust manifold.
4. Remove the converter and inlet gasket from exhaust manifold.
5. Discard inlet gasket.

INSTALLATION
1. Loosely install the converter to the exhaust manifold, using a new inlet gasket.
2. Position outlet gasket onto the converter and loosely install retainers onto outlet flange studs of the converter.
3. Align exhaust system. Ensure muffler converter are fully engaged. Tighten all nuts and bolts, starting at front of system.
4. Tighten the converter retaining nuts to the exhaust manifold and muffler to 34-46 Nm (26-33 ft lb). Tighten retaining bracket bolts to 8-12 Nm (71-106 in lb). Tighten clamp bolt to 20-30 Nm (15-22 ft lb). Tighten exhaust manifold heat shield retainers to 8-12 Nm (71-106 in lb).
5. Install EGR tube to the converter.
6. Check system for leaks and lower vehicle.