Catalytic Converter Replacement 4.3L 4WD and RWD Utility

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Disconnect the heated oxygen sensor (HO2S) electrical connection.
3. Remove the catalytic converter to exhaust manifold pipe flange nuts.



4. Remove the catalytic converter to the muffler flange nuts.
5. Remove the catalytic converter from the muffler.



6. Remove the catalytic converter from the rubber catalytic converter hangers.



7. Remove the catalytic converter and the gasket from the vehicle.
8. Remove the heated oxygen sensors (HO2S) as necessary. Refer to Heated Oxygen Sensor Replacement in Engine Controls 4.3L.

1. Install the heated oxygen sensors (HO2S) as necessary. Refer to Heated Oxygen Sensor Replacement in Engine Controls 4.3L.
2. Install the catalytic converter and new gasket to the exhaust manifold pipe.



3. Install the catalytic converter to the catalytic converter rubber hangers.



4. Install the muffler and new gasket to the catalytic converter.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the catalytic converter to the exhaust manifold pipe flange nuts.

Tighten
Tighten the catalytic converter to the exhaust manifold pipe flange nuts to 35 N·m (26 lb ft).

6. Install the catalytic converter to the muffler flange nuts.

Tighten
Tighten the catalytic converter pipe to the muffler flange nuts to 40 N·m (30 lb ft).




7. Connect the heated oxygen sensor (HO2S) electrical connection.
8. Lower the vehicle.

Catalytic Converter Replacement 4.3L RWD Pickup

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Disconnect the heated oxygen sensor (HO2S) electrical connection.
3. Remove the catalytic converter to exhaust manifold pipe flange nuts.



4. Remove the catalytic converter to the muffler flange nuts.
5. Remove the catalytic converter from the muffler.



6. Remove the catalytic converter from the rubber catalytic converter hanger.



7. Remove the catalytic converter and the gasket.
8. Remove the heated oxygen sensor (HO2S) as necessary. Refer to Heated Oxygen Sensor Replacement in Engine Controls 4.3L.

1. Install the heated oxygen sensor (HO2S) as necessary. Refer to Heated Oxygen Sensor Replacement in Engine Controls 4.3L.
2. Install the catalytic converter and new gasket to the exhaust manifold pipe.



3. Install the catalytic converter to the rubber catalytic converter hanger.



4. Install the muffler and new gasket to the catalytic converter.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the catalytic converter to the exhaust manifold pipe flange nuts.

Tighten
Tighten the catalytic converter to the exhaust manifold pipe flange nuts to 35 N·m (26 lb ft).

6. Install the catalytic converter to the muffler flange nuts.

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




7. Connect the heated oxygen sensor (HO2S) electrical connection.
8. Lower the vehicle.

Catalytic Converter Replacement 2.2L

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Disconnect the heated oxygen sensor (HO2S) electrical connection.



3. Remove the catalytic converter to exhaust manifold pipe flange nuts.



4. Remove the catalytic converter to the muffler flange nuts.
5. Remove the catalytic converter from the muffler.



6. Remove the catalytic converter from the catalytic converter hanger.



7. Remove the catalytic converter from the vehicle.
8. Remove the heated oxygen sensor (HO2S) as necessary. Refer to Heated Oxygen Sensor Replacement in Engine Controls 2.2L.

1. Install the heated oxygen sensor (HO2S) as necessary. Refer to Heated Oxygen Sensor Replacement in Engine Controls 2.2L.
2. Install the catalytic converter and new gasket to the exhaust manifold pipe. Do not tighten the nuts.



3. Install catalytic converter to the catalytic converter hanger.



4. Install the muffler and new gasket to the catalytic converter.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the catalytic converter to the exhaust manifold pipe flange nuts.

Tighten
Tighten the catalytic converter to the exhaust manifold pipe flange nuts to 35 N·m (26 lb ft).

6. Install the catalytic converter to the muffler flange nuts.

Tighten
Tighten the catalytic converter to the muffler flange nuts to 35 N·m (26 lb ft).




7. Connect the heated oxygen sensor (HO2S) electrical connection.
8. Lower the vehicle.