Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSPONTIAC2004AZTEK AWD V6-3.4L VIN EREPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTEMISSION CONTROL SYSTEMSCATALYTIC CONVERTERSERVICE AND REPAIRCATALYTIC CONVERTER REPLACEMENT
2004 Pontiac Aztek AWD V6-3.4L VIN E
Catalytic Converter Replacement
2004 Pontiac Aztek AWD V6-3.4L VIN ESECTION Catalytic Converter Replacement
Catalytic Converter Replacement
Removal Procedure
Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.
1. Raise and support the vehicle.
2. If the vehicle is equipped with All-Wheel-Drive, remove the propeller shaft.
3. Remove the catalytic converter nuts from the exhaust manifold studs.
4. Remove the oxygen sensor.
5. Remove the catalytic converter bolts.
6. Remove the catalytic converter.
Installation Procedure
1. Position and support the catalytic converter under the vehicle.
2. Install a new catalytic converter gasket.
3. Install the catalytic converter bolts. Do not tighten the bolts.
4. Install a new catalytic converter seal.
5. Notice: Refer to Fastener Notice in Service Precautions.
Install the catalytic converter nuts.
1. Tighten the catalytic converter nuts to 34 Nm (25 ft. lbs.).
2. Tighten the catalytic converter bolts to 45 Nm (33 ft. lbs.).
6. Install the oxygen sensor.
7. Lower the vehicle.
Removal Procedure
Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.
1. Raise and support the vehicle.
2. If the vehicle is equipped with All-Wheel-Drive, remove the propeller shaft.
3. Remove the catalytic converter nuts from the exhaust manifold studs.
4. Remove the oxygen sensor.
5. Remove the catalytic converter bolts.
6. Remove the catalytic converter.
Installation Procedure
1. Position and support the catalytic converter under the vehicle.
2. Install a new catalytic converter gasket.
3. Install the catalytic converter bolts. Do not tighten the bolts.
4. Install a new catalytic converter seal.
5. Notice: Refer to Fastener Notice in Service Precautions.
Install the catalytic converter nuts.
1. Tighten the catalytic converter nuts to 34 Nm (25 ft. lbs.).
2. Tighten the catalytic converter bolts to 45 Nm (33 ft. lbs.).
6. Install the oxygen sensor.
7. Lower the vehicle.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.