GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 Engine 🢒 Engine Exhaust 🢒 Catalytic Converter Replacement

Removal Procedure
  1. Remove the wheel drive shaft heat shield. Refer to Wheel Drive Shaft Heat Shield Replacement .
  2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the post catalytic converter heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor 2 Replacement in Engine Controls - 2.2L.

    4. Object Number: 878834 Size: SH
  4. Remove the catalytic converter pipe-to-exhaust manifold nuts.
  5. Carefully separate the converter pipe from the exhaust manifold.
  6. Lower the converter pipe to rest on the rear crossmember of the front suspension frame.

    7. Object Number: 889724 Size: SH
  7. Remove the catalytic converter pipe-to-exhaust extension pipe nuts.
  8. Position the converter pipe forward and support the pipe.
  9. Move the extension pipe rearward and down in order to separate the pipes.
  10. Remove the catalytic converter pipe assembly from the vehicle.
  11. If the exhaust gaskets have remained on the vehicle, remove the gaskets from the exhaust manifold and from the exhaust extension pipe, and discard the gaskets.
  12. Clean the flange surfaces of any remaining gasket material.

Installation Procedure

    Object Number: 889724 Size: SH
  1. Install NEW exhaust gaskets to the exhaust manifold and to the exhaust extension pipe. The gaskets are designed to be retained to the flange by the flange studs.
  2. Position the catalytic converter pipe assembly to the vehicle.
  3. Move the extension pipe rearward and down in order to connect the converter pipe to the extension pipe.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the catalytic converter pipe-to-exhaust extension pipe nuts.

    5. Tighten
    Tighten the nuts to 30 N·m (22 lb ft).

  5. Carefully install the converter pipe to the exhaust manifold.

    6. Object Number: 878834 Size: SH
  6. Install the catalytic converter pipe-to-exhaust manifold nuts.

    7. Tighten
    Tighten the nuts to 50 N·m (37 lb ft).

  7. Install the post catalytic converter HO2S. Refer to Heated Oxygen Sensor 2 Replacement in Engine Controls - 2.2L.
  8. Install the wheel drive shaft heat shield. Refer to Wheel Drive Shaft Heat Shield Replacement .
  9. Lower the vehicle.