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Home >> Saturn >> 2007 >> Relay 3.9 1 >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Catalytic Converter Replacement >> Installation Procedure

Installation Procedure

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.
    Fig 1: Identifying Catalytic Converter (FWD)
    GM1681406Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW gasket onto the muffler studs.
  2. Install a NEW gasket onto the exhaust manifold studs.
  3. Position and install the catalytic converter.
  4. Install the converter to the hanger.
    5. Fig 2: Removing/Installing Catalytic Converter To Muffler Nuts
    GM1681430Courtesy of GENERAL MOTORS CORP.
  5. Install the catalytic converter onto the muffler studs.
    6. Fig 3: Exhaust Manifold Pipe Stud
    GM260064Courtesy of GENERAL MOTORS CORP.
  6. Gently pull back the catalytic converter and muffler assembly until the converter can be installed onto the exhaust manifold studs.
  7. Install the catalytic converter onto the exhaust manifold studs.
  8. Install the catalytic converter to muffler nuts until snug.
    9. NOTE: Refer to Fastener Notice .
  9. Install the catalytic converter to exhaust manifold nuts until snug.

    Tighten: 

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

  10. Remove the jackstand from under the muffler.
    11. Fig 4: Disconnecting/Connecting HO2S Electrical Connector
    GM1681413Courtesy of GENERAL MOTORS CORP.
  11. Connect the H02S electrical connector.
  12. Lower the vehicle.
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