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Home >> Chevrolet >> 2003 >> Impala LS >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Catalytic Converter Replacement (3.8L) >> Installation Procedure

Installation Procedure

    Fig 1: HO2S At Catalytic Converter
    GM372612Courtesy of GENERAL MOTORS CORP.
  1. Install the heated oxygen sensor (HO2S). Refer to HEATED OXYGEN SENSOR .
    2. Fig 2: View Of Catalytic Converter Mounting Nuts
    GM212193Courtesy of GENERAL MOTORS CORP.
  2. Install a new gasket to the exhaust pipe studs.
  3. Install a new gasket to the exhaust manifold.
    4. NOTE: Refer to Catalytic Converter Movement Notice in Cautions and Notices.
  4. Install and support the 3-way catalytic converter.
  5. Install the catalytic converter nuts.
    6. Fig 3: View Of Catalytic Converter & Exhaust Manifold Pipe Stud Nuts
    GM372626Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the exhaust manifold pipe stud nuts.

    Tighten: 

    • Tighten the exhaust manifold pipe stud nuts to 35 N.m (26 lb ft).
    • Tighten the catalytic converter nuts to 60 N.m (44 lb ft).

    7. Fig 4: View Of Catalytic Converter Hangers
    GM289493Courtesy of GENERAL MOTORS CORP.
  7. Install the catalytic converter hangers.
  8. Connect the heated oxygen sensor (HO2S) electrical connector.
  9. Lower the vehicle.
  10. Inspect the exhaust system for leaks.
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