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. Disconnect heated oxygen sensor electrical connectors.
3. Remove the retaining bolts at each three-way catalytic converter flange.
4. Remove the three-way catalytic converter to exhaust manifold retaining nuts.
5. Slide the exhaust inlet pipe rearward until the three way catalytic converters can be removed. It may be necessary to obtain sufficient clearance to separate the three way catalytic converter at exhaust manifold connection(s).
6. Discard exhaust converter outlet gaskets and any damaged parts.


INSTALLATION
1. Remove exhaust converter outlet gasket material from exhaust inlet pipe and the three way catalytic converters.
2. Position the three way catalytic converters to the exhaust manifolds. Loosely install retaining nuts.
3. Install new exhaust converter outlet gaskets between the three way catalytic converters and exhaust inlet pipe flanges. Position the exhaust inlet pipe flange to the three-way catalytic converter outlet flange and insert new retaining bolts.
4. Alternately tighten the three way catalytic converter to the exhaust inlet pipe flange retaining bolts to 34-46 Nm (26-33 ft. lbs.).

NOTE: Alternate tightening of the joint fastener is required to provide uniform clamping. This will prevent joint distortion, a major cause of system leaks and misadjustment.

5. Align the system to proper clearance specification.

6. Alternately tighten the exhaust manifold nuts to 34-46 Nm (26-33 ft. lbs.).
7. Connect heated oxygen sensor electrical connectors.
8. Check the system for leaks.
9. Lower vehicle.