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Home >> Chevrolet >> 2004 >> Impala SS >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Catalytic Converter Replacement (3.8L) >> Installation Procedure

Installation Procedure

  1. Install the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Position 2 in Engine Controls - 3.8L.
    2. Fig 1: Installing HO2S To Catalytic Converter (3.8L)
    GM372612Courtesy 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 2: View Of Catalytic Converter Mounting Nuts
    GM212193Courtesy 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 3: View Of Catalytic Converter & Exhaust Manifold Pipe Stud Nuts
    GM372626Courtesy of GENERAL MOTORS CORP.
  7. Install the catalytic converter hangers.
    8. Fig 4: View Of Catalytic Converter Hangers
    GM289493Courtesy of GENERAL MOTORS CORP.
  8. Connect the heated oxygen sensor (HO2S) electrical connector.
  9. Lower the vehicle.
  10. Inspect the exhaust system for leaks.
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