Catalytic Converter: Service and Repair

Catalytic Converter Replacement (RPOs L26/L32)
Removal Procedure





1. Important: The catalytic converter is serviced by replacing the entire assembly. Always replace the gaskets at the front and rear flanges when servicing the catalytic converter. Never install the original gasket.

Raise and support the vehicle. Refer to Vehicle Lifting.
2. Disconnect the heated oxygen sensor (HO2S) electrical connector.
3. Remove the catalytic converter pipe stud nuts (2).
4. Remove the catalytic converter pipe gasket (1).
5. Support the exhaust system.





6. Remove the catalytic converter nuts.





7. Remove the catalytic converter hangers.
8. Remove the catalytic converter.
9. Remove the catalytic converter gasket.
10. Clean and inspect the exhaust manifold and the exhaust pipe gasket mating surfaces.
11. Remove the HO2S.

Installation Procedure





1. Install the HO2S.

2. Install a new gasket to the exhaust pipe studs.

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.

3. Install and support the catalytic converter.

4. Install the catalytic converter nuts.
Tighten the nuts to 60 Nm (44 ft. lbs.).

Notice: Refer to Fastener Notice in Service Precautions.






5. Install a new catalytic converter pipe gasket (1).
6. Install the catalytic converter pipe stud nuts (2).
Tighten the nuts to 35 Nm (26 ft. lbs.).





7. Install the catalytic converter hangers.
8. Remove the support from the exhaust system.
9. Connect the HO2S electrical connector.
10. Inspect the exhaust system for leaks and underbody contact.
11. Lower the vehicle.