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Home >> Saturn >> 2005 >> Relay AWD >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Catalytic Converter Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: View Of Catalytic Converter Mounting Nuts
    GM212193Courtesy of GENERAL MOTORS CORP.
    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.
  1. Install a new catalytic converter gasket.
  2. Install a new exhaust manifold pipe gasket.
  3. Position and support the new 3-way catalytic converter under the vehicle.
  4. Install the exhaust pipe to the 3-way catalytic converter with the catalytic converter nuts. Do not tighten the nuts.
  5. Fig 2: Exhaust Manifold Pipe Stud
    GM260064Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the exhaust manifold pipe nuts to the exhaust manifold pipe studs.

    Tighten: 

    • Tighten the exhaust manifold pipe nuts to the exhaust manifold pipe stud to 35 N.m (26 lb ft).
    • Tighten the catalytic converter nuts to 34 N.m (25 lb ft).

  7. Connect the heated oxygen sensor connector.
  8. Lower the vehicle.