Service Procedure
INSPECTION AND REPLACEMENT OF CATALYTIC CONVERTERCAUTION:
MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE ADDITIONAL SUPPORT TO OPPOSITE END OF VEHICLE THAT COMPONENTS WILL BE REMOVED FROM. ENSURE HOIST DOES NOT CONTACT FUEL OR BRAKE LINES.
1. Raise vehicle on hoist.
IMPORTANT:
If catalytic converter has previously been replaced with a non-Saturn part, continue to step 4.
2. Inspect catalytic converter date code stamp in area (A) indicated in illustration. Date code stamp is a six digit number on passenger side and will be facing downward.
^ If date code stamp cannot be read or catalytic converter has previously been replaced with a non-Saturn part, continue to step 4.
^ When read from left to right, if fourth digit of date code stamp is 4 or greater, no further repair is necessary. Affix Campaign Completion Label.
^ When read from left to right, if fourth digit of date code stamp is 3, continue to step 3.
3. Inspect first three digits of date code stamp.
^ When read from left to right, if first three digits of date code stamp are greater than or equal to 272, no further repair is necessary. Affix Campaign Completion Label.
^ When read from left to right, if first three digits of date code stamp are less than 272, continue to step 4.
NOTICE:
Always use a chain cutter to cut stainless steel exhaust system pipes. A torch leaves a rough edge and warps end of pipe, preventing good exhaust system sealing.
4. Using chain cutter SA9168NE (or equivalent) cut catalytic converter inlet pipe off approximately 19 mm (3/4 in.) from front edge of hanger bracket.
A. 19 mm (3/41n.)
5. Remove three catalytic converter to intermediate pipe nuts and remove converter from vehicle.
6. Remove catalytic converter isolators.
7. Obtain the following service replacement parts:
^ Catalytic converter kit
(P/N 21006671)
^ One exhaust system clamp
(P/N 15595048)
8. File burrs from inside front exhaust pipe.
9. Clean converter flange surface on intermediate pipe with a wire brush.
IMPORTANT:
The sleeve included with replacement catalytic converter is only required if a service front exhaust pipe is installed on vehicle.
10. Install new bolts and gasket onto outlet flange of replacement catalytic converter.
11. Install exhaust system clamp on converter inlet.
12. Position catalytic converter under vehicle with drain holes facing down.
13. Slide end of converter inlet over front exhaust pipe.
14. Install catalytic converter outlet flange to intermediate pipe and ensure converter is properly located.
15. Install catalytic converter to intermediate pipe nuts.
Torque: 31 N.m (23 ft-lbs)
16. Install two catalytic converter isolators.
17. Check exhaust system alignment.
IMPORTANT:
Always use correct size exhaust system clamp to prevent exhaust leaks.
18. Position exhaust system clamp 19 mm (3/4 in.) from cut edge of front pipe.
19. Rotate and position clamp on pipe to ensure no contact with heat shield.
20. Tighten clamp nuts evenly.
Torque: 60 N.m (44 ft-lbs)
21. Start vehicle and check entire exhaust system for exhaust leaks.
22. Affix Campaign Completion Label.