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Catalytic Converters: Installation

WARNING: This page is about a different car, the 2003 Chevrolet Corvette and 2002 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials.
  1. With the aid of an assistant, install the catalytic converter assembly to the jack stands.
  2. Raise the jack stands in order to position the catalytic converter assembly.
  3. Install NEW exhaust muffler gaskets.
  4. Install all exhaust bolts until snug to ensure correct alignment of the catalytic converter assembly.
  5. Remove the adjustable jack stands.
    6. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. DO NOT use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  6. Tighten the exhaust muffler bolts to specification in the following sequence:
    1. Left inboard
    2. Left outboard
    3. Right inboard
    4. Right outboard
  7. Tighten the exhaust pipe-to-exhaust manifold nuts to specification. See TORQUE SPECIFICATIONS .
  8. Tighten the exhaust pipe brace bolts to specification.
  9. Tighten the exhaust pipe hanger bolts to specification.
    10. CAUTION: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning solvents on the sensor. Do not drop or mishandle the sensor.
  10. Apply Anti-Seize compound (GM 12377953) or equivalent to the threads of the oxygen sensors.
  11. Tighten the oxygen sensors to specification. See TORQUE SPECIFICATIONS .
  12. Install the oxygen sensor clips to the heat shields.
  13. Connect the oxygen sensor electrical connectors.
  14. Install the oxygen sensor Connector Position Assurance (CPA) locks.
  15. Lower the vehicle.
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