Catalytic Converter: Service and Repair

WARNING: Make sure vehicle is properly supported and squarely positioned prior to lifting. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. Make sure hoist does not contact fuel or brake lines.



REMOVAL
1. Raise vehicle squarely on a lift.

NOTE: Always use a chain cutter to cut the stainless steel exhaust system pipes. A torch leaves a rough edge and warps the pipe end, preventing good exhaust system sealing.

Cutting Exhaust Pipe At Converter:

2. Using chain cutter (Saturn Tool) SA9168 NE (or equivalent) cut the three way catalytic converter inlet pipe off just forward of the insulator hanger bracket leaving 50.8 mm (2 in.) of front exhaust pipe outlet.
3. Remove the three nuts that fasten the three way catalytic converter to the intermediate pipe. Save the fasteners.
4. Remove the three way catalytic converter isolators and discard the gasket and three way catalytic converter.

INSTALLATION

Converter Installation:

1. Remove burrs from inside front exhaust pipe with a file.
2. Clean the intermediate pipe-to-three way catalytic converter flange surface.
3. Install a new gasket on the intermediate inlet pipe-to-three way catalytic converter outlet pipe.
4. Position service three way catalytic converter under vehicle with the drain holes directed downward.

Exhaust Pipe Sleeve:

5. Slide the three way catalytic converter inlet end into the front exhaust pipe outlet.

NOTE: The sleeve furnished with each three way catalytic converter is required when both a service three way catalytic converter and service front pipe are installed. The sleeve should be retained with the vehicle for possible future use if only the three way catalytic converter is replaced.

Sleeve Dimensions:
Inside Diameter: 54.7 mm (25/32 in.) Length: 46 mm (1 13/16 in.)

6. Make sure the three way catalytic converter gasket is properly located. Install the three intermediate pipe-to-three way catalytic converter fasteners.

Torque to 31 N.m (23 ft-lbs)

7. Install the two three way catalytic converter isolators.
8. Check system for alignment.
9. Install the correct service clamp assembly.

Three Way Catalytic Converter Clamps:
^ Service three-way catalytic converter to service front exhaust pipe or OE front exhaust pipe Saturn P/N 15595048

^ OE three-way catalytic converter to service front exhaust pipe Saturn P/N 25525694

10. Position the slip joint clamp 19 mm (3/4 in.) from the pipe's cut off end. Tighten the slip joint clamp, positioned to prevent shield contact.

Torque to 60 N.m (44 ft-lbs)

NOTE: Always use the correct size clamp to prevent exhaust leaks.

11. Check the entire exhaust system for alignment and leaks.