Catalytic Converter Replacement Gasoline Engines

Warning: Refer to Battery Disconnect Warning in the Preface section.




1. Disconnect the negative battery cable.

Caution: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning solvents on the sensor. Do not drop or mishandle the sensor.

2. Disconnect the oxygen sensor electrical connector.
3. Remove the exhaust manifold cover with the bolts.




Important: The nuts and the stud may unscrew as a unit because of the high temperature associated with the exhaust manifold, but they can be re-used as such.

4. Remove the catalytic converter upper flange nuts.



5. Remove the exhaust front pipe mounting bracket bolt.
6. Remove the nuts from the exhaust front pipe-to-catalytic converter flange.
7. Remove the catalytic converter and the gasket.
8. Clean the sealing surfaces on the exhaust front pipe flange and the exhaust manifold.
9. Inspect the exhaust front pipe and the exhaust manifold for holes, damage, open seams or other deterioration which could permit exhaust fumes to seep into the passenger compartment.

Caution: Refer to Fastener Caution in the Preface section.




1. Install the catalytic converter and the gasket to the exhaust front pipe flange.

Tighten

•	Tighten the exhaust front pipe-to-catalytic converter nuts to 40 N·m (30 lb ft).

•	Tighten the exhaust front pipe-to-cylinder block bolt to 50 N·m (37 lb ft).




2. Install the catalytic converter to exhaust manifold nuts and the gasket.

Tighten
Tighten the catalytic converter to exhaust manifold nuts to 40 N·m (30 lb ft).




3. Install the exhaust manifold cover bolts.

Tighten
Tighten the exhaust manifold cover bolts to 15 N·m (11 lb ft).

4. Connect the oxygen sensor electrical connector.
5. Connect the negative battery cable.

Catalytic Converter Replacement Diesel Engine

Warning: Refer to Battery Disconnect Warning in the Preface section.





Warning: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials.

1. Disconnect the negative battery cable.
2. Remove the exhaust manifold heat shield.



3. Remove the exhaust front pipe.
4. Remove the pre-catalyst clamp.
5. Remove the pre-catalyst bracket bolt from the engine block.
6. Remove the pre-catalyst with the seal ring.

1. Install the pre-catalyst with the seal ring. If damaged, replace the new seal ring.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the pre-catalyst clamp and the bracket bolt.

Tighten
Tighten the pre-catalyst bracket bolt to 40 N·m (29.5 lb ft).

3. Install the exhaust front pipe. Refer to Front Pipe Replacement.



4. Install the exhaust manifold heat shield.

Tighten
Tighten the exhaust manifold heat shield bolt and nut to 20 N·m (14.8 lb ft).

5. Connect the negative battery cable.