Catalytic Converter: Service and Repair

Removal Procedure

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

Notice: When jacking or lifting the vehicle from the frame side rails, be certain lift pads do not contact the three-way catalytic converter as damage to the converter will result.

Notice: Replacement of exhaust system parts must be OEM standard to ensure that the vehicle operates as designed.

1. Raise and suitably support the vehicle.





2. Disconnect the Heated Oxygen Sensor (H02S) electrical connection.





3. Remove the catalytic converter to exhaust manifold pipe flange nuts.





4. Remove the muffler to the catalytic converter flange nuts.
5. Remove the muffler from the catalytic converter.





6. Remove the catalytic converter from the catalytic converter hanger.
7. Remove the catalytic converter from the vehicle.
8. Remove the Heated Oxygen Sensor (H02S) as necessary.

Installation Procedure





1. Install the Heated Oxygen Sensor (H02S) as necessary.
2. Install the catalytic converter and new gasket to the vehicle.
3. Install catalytic converter to the catalytic converter hanger.





4. Install the muffler and new gasket to the catalytic converter.
5. Install the muffler to the catalytic converter flange nuts.
Tighten the muffler to the catalytic converter flange nuts to 35 Nm (26 ft. lbs.).





6. Install the catalytic converter to the exhaust manifold pipe flange nuts.
Tighten the catalytic converter to the exhaust manifold pipe flange nuts to 35 Nm (26 ft. lbs.).





7. Connect the Heated Oxygen Sensor (H02S) electrical connection.
8. Lower the vehicle.