Catalytic Converter: Removal

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.

NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to POWERTRAIN DIAGNOSTIC PROCEDURES article for repair procedures.

Loosen intermediate pipe-to catalytic converter clamp.
NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water.
Remove muffler/intermediate pipe insulators as necessary to slide muffle/intermediate pipe assembly out of catalytic converter.
1.6L Engine - Disconnect upstream oxygen sensor electrical connector.
Disconnect downstream oxygen sensor electrical connector. See Fig 1.

Fig 1: Downstream 1/2 Oxygen Sensor - Typical
Courtesy of DAIMLERCHRYSLER CORP.

1 - DOWN STREAM O2 SENSOR

2 - UP STREAM O2 SENSOR
Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle. See Fig 2, Fig 3, Fig 4 or Fig 5.
Remove and discard flange gasket.