CATALYTIC CONVERTER REPLACE. PROCEDURE OUTLINED. Chevrolet Beretta 1987

For 1990-2009 cars

# CATALYTIC CONVERTER REPLACE. PROCEDURE OUTLINED

#### Model and Year: 1987-88 BERETTA, CORSICA

If it should become necessary to replace a catalytic converter on a 1987-88 Beretta, Corsica, the following procedure should be followed:

#### CATALYTIC CONVERTER REPLACEMENT

1. Raise vehicle on hoist.

2. Remove exhaust system hangers at front and rear of muffler and behind the catalytic converter.

3. Remove exhaust pipe from exhaust manifold.

4. Lower exhaust system as far as possible.

5. With a hacksaw or suitable tool, cut the catalytic converter extension just rearward of the rear weld (See Figure 1) and remove the converter and exhaust pipe from the vehicle.

6. Place the converter/exhaust pipe assembly on a suitable working surface and cut the remaining converter extension just forward of the forward weld (See Figure 1).

7. Remove any burrs from the outside diameter (OD's) of the exhaust pipe and intermediate pipe where cuts were made.

8. Reinstall the exhaust pipe and tighten the manifold attaching nuts 20-30 Nm (15-22 ft. lbs.)

9. Install stainless steel service pipe, P/N 10093261, on the open end of the exhaust pipe. Install a 2 inch exhaust clamp (See Figure 2) and tighten 27-35 Nm (20-25 ft. lbs.).

10. Install a new catalytic converter. IMPORTANT. THE STAMPED DIMPLES ON THE CONVERTER GO TO THE FRONT OF THE VEHICLE (See Figures 1 and 2).

11. Install 2 inch exhaust clamps on each end of the new converter (See Figure 2). Do not tighten.

12. Insert intermediate pipe into the rear of the catalytic converter and loosely install the rear muffler hanger bolt.

13. Align and install the intermediate exhaust pipe hanger bolt behind the catalytic converter and at the forward end of the muffler.

14. Install and tighten the exhaust hanger bolt on the forward end of the muffler 40-54 Nm (30-40 ft. lbs.).

15. Tighten the remaining exhaust hanger bolts.

#### CAUTION:

DO NOT TIGHTEN THE 2 INCH EXHAUST SYSTEM CLAMPS ON THE CONVERTER UNTIL COMPLETION OF STEP 16.

1. Front muffler hanger 40-54 Nm (30-40 ft. lbs.).

2. Intermediate pipe hanger 20-30 Nm (15-22 ft. lbs.).

16. Align the catalytic converter so the flanges are parallel with the vehicle underbody and the intermediate pipe is inserted 1-1/4 inches inside the converter.

17. Tighten the 2 inch exhaust system clamp at the rear of the converter (See Figure 2) 27-35 Nm (20-25 ft. lbs.).

18. Tighten the 2 inch exhaust system clamp at the front of the converter (See Figure 2) 27-35 Nm (20-25 ft. lbs.).

19. Check the system alignment. The catalytic converter should have a minimum of 1 inch clearance between any surface and the heat shield attached to the vehicle underbody. All exhaust system pipes should have sufficient clearance to prevent contact.

20. Lower vehicle.

Labor Operation Number: L2300

Labor Time: 1.2 Hours

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