GM Service Manual Online
For 1990-2009 cars only

Auxiliary Catalytic Converter Replacement 2.0L Diesel

Removal Procedure

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


    Object Number: 1758662  Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the engine under cover.
  3. Remove the exhaust manifold heat shield with the bolts.

  4. Object Number: 1774815  Size: SH

    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.

  5. Remove the pup converter upper flange-to-exhaust manifold retaining nuts.

  6. Object Number: 1758551  Size: SH
  7. Remove the pup converter-to-exhaust front pipe retaining nuts.
  8. Remove the exhaust front pipe mounting bracket bolt and nut.
  9. Remove the pup converter and the gasket.
  10. Clean the sealing surfaces on the exhaust front pipe flange and the exhaust manifold.
  11. Check 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.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1774815  Size: SH
  1. Install the pup converter upper flange nuts and the gasket to exhaust manifold.
  2. Tighten
    Tighten the pup converter upper flange nuts to 40 N·m (30 lb ft).


    Object Number: 1758551  Size: SH
  3. Install the pup converter and the gasket to the exhaust front pipe flange.
  4. Tighten

        • Tighten the pup converter-to-exhaust front pipe retaining nuts to 40 N·m (30 lb ft).
        •  Tighten the exhaust front pipe mounting bracket bolt and nut to 40 N·m (30 lb ft).

    Object Number: 1758662  Size: SH
  5. Install the exhaust manifold heat shield.
  6. Tighten
    Tighten the exhaust manifold heat shield bolts to 15 N·m (11 lb ft).

  7. Install the engine under cover.
  8. Connect the negative battery cable.

Auxiliary Catalytic Converter Replacement 3.2L

Removal Procedure

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


    Object Number: 1860095  Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the exhaust front pipe. Refer to Front Pipe Replacement.

  3. Object Number: 1860097  Size: SH
  4. Remove the bank 2 pup converter upper flange-to-bank 2 exhaust manifold retaining nuts, 3 places.
  5. 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 reused as such.

  6. Remove the bank 2 pup converter and gasket.

  7. Object Number: 1860099  Size: SH
  8. Remove the bank 1 pup converter upper flange-to-bank 1 exhaust manifold retaining nuts, 2 places.
  9. 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 reused as such.

  10. Remove the bank 1 pup converter and the gasket.
  11. Clean the ceiling surfaces on the exhaust front pipe and both of the exhaust manifolds.
  12. Check the exhaust front pipe and both of the exhaust manifolds for holes, damage, open seams or other deterioration which could permit exhaust fumes to seep into the passenger compartment.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1860097  Size: SH
  1. Install the gasket and the bank 2 pup converter upper flange-to-bank 2 exhaust manifold retaining nuts, 3 places.
  2. Tighten
    Tighten the bank 2 pup converter upper flange nuts to 40 N·m (30 lb ft).


    Object Number: 1860099  Size: SH
  3. Install the gasket and the bank 1 pup converter upper flange-to-bank 1 exhaust manifold retaining nuts, 2 places.
  4. Tighten
    Tighten the bank 1 pup converter upper flange nuts to 40 N·m (30 lb ft).


    Object Number: 1860095  Size: SH
  5. Install the exhaust front pipe. Refer to Front Pipe Replacement.
  6. Tighten
    Tighten the pup converter-to-exhaust front pipe retaining nuts to 40 N·m (30 lb ft).