Catalytic Converter: Service and Repair

Catalytic Converter Replacement

Removal Procedure

Notice: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting Position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.

1. Disconnect oxygen sensor.
2. Raise the vehicle. Refer to Vehicle Lifting.
3. Support the three way catalytic converter.
4. Support the exhaust manifold pipe.





5. Remove the three way catalytic converter bolts from the intermediate pipe.





6. Remove the exhaust manifold pipe bolts.
7. Remove the three way catalytic converter from the exhaust manifold pipe.
8. Remove the three way catalytic converter and seals.
9. Clean the flange surfaces.

Installation Procedure

1. Install the three way catalytic converter seals.

Notice: Refer to Fastener Notice in Service Precautions.





2. Install the three way catalytic converter to the intermediate pipe.
Tighten the intermediate pipe bolts to 30 Nm (22 ft. lbs.).
3. Install the three way catalytic converter to the exhaust manifold pipe.





4. Install the exhaust manifold pipe bolts.
Tighten the exhaust manifold pipe bolts to 45 Nm (33 ft. lbs.).
5. Lower the vehicle.
6. Connect oxygen sensor.