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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1318 (Engine Exhaust System) >> Repair Instructions >> Catalytic Converter Replacement (3.8L) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Refer to FASTENER NOTICE .
  1. Install the heated oxygen (HO2S) sensor. Refer to HEATED OXYGEN SENSOR .
    Fig 1: Heated Oxygen (HO2S) Sensor
    G01704102Courtesy of GENERAL MOTORS CORP.
  2. Install a new exhaust manifold pipe gasket to the exhaust manifold pipe studs.
    NOTE: 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 three way catalytic converter.
  4. Install the exhaust manifold pipe stud nuts.

    Tighten 

    Tighten the exhaust manifold pipe stud nuts to 35 N.m (26 lb ft).

    Fig 2: Install Exhaust Manifold Pipe Gasket & Pipe Stud Nuts
    G01704103Courtesy of GENERAL MOTORS CORP.
  5. Install the catalytic converter gasket.
  6. Install the catalytic converter bolts.

    Tighten 

    Tighten the catalytic converter bolts to 45 N.m (33 lb ft).

  7. Connect the heated oxygen (HO2S) sensor wiring harness connector and retainers.
  8. Remove the support from the exhaust system.
  9. Inspect the exhaust system for leaks and underbody contact.
  10. Lower the vehicle.
    Fig 3: Catalytic Converter Gasket, Stud Nuts & Heated Oxygen (HO2S) Sensor
    G01704104Courtesy of GENERAL MOTORS CORP.
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