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Home >> Pontiac >> 2004 >> Sunfire Automatic >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Catalytic Converter Replacement >> Removal Procedure

Removal Procedure

NOTE: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the post catalytic converter heated oxygen sensor.
    Fig 1: View Of HO2S 2
    GM10975Courtesy of GENERAL MOTORS CORP.
  3. Support the three-way catalytic converter.
  4. Remove the intermediate pipe bolts.
    Fig 2: Exploded View Of Intermediate Pipe Bolts
    GM25258Courtesy of GENERAL MOTORS CORP.
  5. Remove the exhaust manifold nuts (3).
    Fig 3: Locating Exhaust Manifold To Flex Decoupler Nuts
    GM783174Courtesy of GENERAL MOTORS CORP.
  6. Remove the three-way catalytic converter and seals.
  7. Clean the flange surfaces.
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