how to remove catalytic converter

Catalytic Converter

At G Exhaust, we believe that your vehicle should always perform at an optimal level. Sometimes, people have a catalytic converter that needs to be repaired, and at other times, people just want to upgrade their catalytic converter. When it comes to removing an old catalytic converter and installing a new one, we recommend you leave it to the professionals. When you bring your car to G Exhaust, you know you are dealing with professionals who know how to replace a catalytic converter. Here's a short step by step on how to replace a catalytic converter.

Catalytic Converter Removal

Step 1: Raise Your Vehicle

The first thing you need to do is to get your whole car off the floor, not just one corner like a tire replacement. Make sure you do this on a level spot, or you risk severe injury or death if the jacks fail. Using a professional quality hydraulic lift is ideal for this job.

Step 2: Allow Vehicle's Exhaust To Cool

Let the exhaust of your vehicle cool after running, the exhaust system may still be hot. This may take a few minutes.

Step 3: Locate the Catalytic Converter

Slide under the vehicle. The catalytic converter should look like a rounded or rectangular box in the middle of the exhaust system. It may also be cylindrical.

Step 4: Remove Oxygen Sensor From Catalytic Converter

Most modern catalytic converters have one or more oxygen sensors that always monitor the efficiency of the exhaust system. If the sensor is attached, use a ratchet wrench and oxygen sensor socket to disconnect it before moving on.

Step 5: If The Catalytic Converter Is Bolted, Apply Penetrating Oil To Bolts

Bolted catalytic converter can have rusted bolts, corroded bolts, or jammed bolts into their nuts. These nuts may be difficult to remove. Loosen them up by applying penetrating oil to them. Let the oil seep into the bolts and lubricate them. This may take several minutes. Do not attempt to remove the bolts for at least a few minutes.

Step 6: First Remove The Bolts At The Back End, Then The Front

Begin loosening the bolts with a wrench before removing them. When the bolts are loosened, remove the rear bolts first (the ones closer to the open end of the exhaust) and then remove the front ones (further away). When you are done, remove the converter. You will probably need to support the exhaust after the catalytic converter removal.

Step 7: For Welded-in Converters, Cut It Out

If the catalytic converter is welded into the exhaust system, you need to remove it physically by cutting it out of the connecting pipes. You can do this with a sawzall or similar tool. Cut along the existing weld lines, after the catalytic converter is cut free, remove it.

Catalytic Converter Installation

Step 1: If there are instructions, defer to them

This step by step guide is written for general cases of installing a catalytic converter. The parts and installation process can be different from car to car, so this guide may not have the best instructions to replace your converter. Always try to follow the instructions that came with your replacement part or consult with a professional. Catalytic converters have a direction that they flow and an arrow for the direction of the exhaust flow.

Step 2: Insert Gaskets Supplied with New Catalytic Converter

There are catalytic converters that come with small, round gaskets that are in the pipes that connect to the converter, giving the converter a more secure fit. If your converter came with gaskets, install them as provided in the instructions before proceeding.

Step 3: Put Catalytic Converter in Place

Place the catalytic converter in the position where it will be installed. Make sure it is pointed in the right direction and that the side that is supposed to face down is facing down.

Step 4: Finger-Tighten Nuts on Bolts

Re-insert bolts and use your hand to tighten them.

Step 5: Tighten Down Bolts

Tighten bolts with the right-sized wrench starting from the front end of the converter. Do the back end after finishing with the front.

Step 6: If You Need to, Weld the Converter into Place

To do this, you will need a professional-grade welding machine and proper training necessary to use it safely. Do not do this if you do not have the expertise, you can damage the vehicle or hurt yourself.

Step 7: Screw Oxygen Sensor back in Place

If you had to remove the oxygen sensor to access the converter, replace it now. Check and make sure that the wiring is secure and not damaged.

After completing all of the necessary work, it is important that you double-check all of your work. This job required a lot of knowledge and expertise, so we highly recommend bringing your car into G Exhaust.