Catalytic Converter: Service and Repair
^ Tools Required
- SA9603E
Removal
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. 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.
NOTICE: The front exhaust pipe and catalytic converter are only serviced as an assembly; components are not serviced separately.
1. Raise vehicle squarely on a lift.
NOTICE: Do not apply grease or silicon products to the heated oxygen sensor (H02S-2). Do not alter the wiring in any way. The wires carry air reference to the sensor.
2. Remove H02S-2 wiring harness from cradle by pushing up on retaining clip tab.
3. Remove Connector Position Assurance (CPA) device and disconnect H02S-2 harness connector.
4. Remove H02S-2 wiring harness from trough in converter heat shield by gently pulling wiring harness from its retaining clips.
5. Remove H02S-2 using Saturn tool SA9603E. If necessary use a liquid penetrate before removing sensor.
IMPORTANT: The H02S-2 uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.
Rear Oxygen Sensor:
6. Remove (3) front exhaust pipe nuts (13 mm hex) at manifold.
7. Loosen front exhaust pipe clamp (15 mm hex) at engine block bracket and slide clamp out of engagement with bracket.
8. Remove (3) nuts (13 mm hex) at the outlet of the catalytic converter to intermediate pipe.
9. Disengage (2) rubber isolators from hanger rod on front exhaust pipe and remove pipe from vehicle.
10. Inspect the front exhaust pipe-to-exhaust manifold flange.
Front Exhaust Pipe to Manifold Flange Warpage:
Standard: 0.7 mm (0.028 inch) max.
Service Limit: 0.7 mm (0.028 inch) max.
Installation
NOTICE: When installing a replacement front exhaust pipe and catalytic converter assembly, (3) bolts and (3) nuts will be required to make the installation to the intermediate pipe. The replacement front exhaust pipe has a 6-hole flange at the outlet of the converter (vs. (3) studs on the production assembly).
1. Install a new gasket on exhaust manifold studs.
2. Install the (2) rubber isolators supporting the front exhaust pipe to the hanger rod on the pipe.
3. Install front exhaust pipe-to-manifold nuts (13 mm hex).
Torque: 31 Nm (23 inch lbs.)
NOTICE: When installing a replacement front exhaust pipe, procure an exhaust pipe hanger clamp for installation on the pipe.
4. Slide front exhaust pipe clamp over engine block bracket and tighten clamp (15 mm hex).
Torque: 60 Nm (44 ft. lbs.)
Rear Oxygen Sensor:
5. Install catalytic converter outlet gasket and fasten outlet to intermediate pipe with (3) nuts.
Torque: 25 Nm (19 ft. lbs.)
NOTICE: Always use a pickle-based anti-seize compound (Saturn P/N 21485279 or equivalent) on the threads of the heated oxygen sensor (H02S-2). If the H02S-2 is replaced, do not apply anti-seize to the new sensor. New sensors have anti-seize pre-applied. Never use silicone products; silicone products will damage the sensor.
6. Install heated oxygen sensor (HO2S)2 using Saturn tool SA9603E.
Torque: 45 Nm (33 ft. lbs.)
7. Attach the H02S-2 harness to the clips on the converter heat shield.
8. Connect H02S-2 harness to connectors and install connector position assurance clip.
9. Install tab on harness connector to the hole in engine cradle.
10. Lower vehicle to ground, start engine, and check for exhaust leaks.