Catalytic Converter: Service and Repair

REPLACEMENT OF CATALYTIC CONVERTERS

1. REMOVE CONVERTERS
(a) Jack up the vehicle.
(b) Check that the converter is cool.
(c) Remove the suspension lower crossmember.





(d) Remove the front exhaust pipe (Sub-converter).
- Loosen the bolt, and disconnect the clamp the exhaust pipe bracket.
- Remove the three nuts, and remove the exhaust pipe. Remove the gasket.
(e) Remove the six bolts, two nuts and two converter stays.
(f) Remove the three bolts, two nuts, gasket, retainer, cushion and main converter.
(g) Remove the nine bolts and two heat insulators from the main converter.





2. INSTALL CONVERTERS
(a) Install the two heat insulators to the main converter with the nine bolts.
(b) Place new cushion, retainer and gasket on the main converter.
(c) Install the main converter with the three bolts and two nuts. Torque the bolts and nuts.

Torque: 300 kg-cm (21 ft-lb, 29 N m)

(d) Install the two converter stays with the six bolts.

Torque: 650 kg-cm (47 ft-lb, 64 N.m)

(e) Install the front exhaust pipe (Sub-converter).
- Place new two gaskets on the exhaust pipe.
- Install the exhaust pipe with the two bolts and five nuts.

Torque:
To converter 630 kg-cm (46 ft-lb., 62 N m)
To center exhaust pipe 440 kg-cm (32 ft-Ib., 43 N.m)

- Install the exhaust pipe clamp with the bolt.
(f) Install the suspension lower crossmember