Catalytic Converter: Service and Repair
EXHAUST SYSTEMCATALYTIC CONVERTER
REMOVAL
WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.
1. Raise vehicle on hoist.
2. Loosen exhaust extension pipe band clamp.
NOTE: Do not use petroleum-based lubricants when removing/installing exhaust pipe isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water.
3. Dislodge exhaust system hangers from support isolators. Separate extension pipe from catalytic converter.
4. Disconnect downstream oxygen sensor electrical connector.
5. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle.
6. Remove and discard the flange gasket.
INSTALLATION
NOTE: When assembling exhaust system do not tighten clamps until all components are aligned and clearances are checked.
1. Loosely assemble catalytic converter to exhaust manifold connection. Use a new flange gasket
2. Connect extension pipe to catalytic converter.
3. Insert exhaust system hangers into support isolators.
4. Tighten the catalytic converter to exhaust manifold fasteners to 28 Nm (250 in. lbs.).
CAUTION: Exhaust band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block Once this occurs, the clamp has lost clamping force and must be replaced.
5. Tighten extension pipe band clamp to 47 Nm (35 ft. lbs.).
6. If removed, install downstream oxygen sensor.
7. Connect downstream oxygen sensor electrical connector,
8. Lower vehicle.
9. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
10. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.