Catalytic converter is possibly clogged

Tiny
IAN MENGLOI
  • MEMBER
  • 2002 NISSAN ALTIMA
  • 2.5L
  • 4 CYL
  • AUTOMATIC
  • 10,000 MILES
And the bolts are rusted on. What should I do to change it? I have a whole muffler with the flex pipe. Is it possible to change it?
Monday, March 30th, 2020 AT 12:45 AM

2 Replies

Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
Good morning,

The rusted bolts either need to be heated up with a torch or cut off with a air tool to remove the bolts.

You need to replace the converter with a replacement. Bypassing it will not work as you will have a check engine light and on top of that, it is a federal violation to remove the converter.

Also, you will not be able to pass smog inspection without the converter installed.

REMOVAL
1. Remove engine under cover, with power tool.

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2. Disconnect the electrical connector of each heated oxygen sensor, and unhook the harness from the bracket and middle clamp on the cover.
3. Remove the heated oxygen sensors with Tool.

CAUTION:
Be careful not to damage heated oxygen sensor.
Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 inch) onto a hard surface such as a concrete floor; use a new one.

4. Remove the lower exhaust manifold cover.
5. Remove the exhaust front tube.
6. Remove the upper exhaust manifold cover.

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7. Loosen the nuts in the sequence shown, on the exhaust manifold and three way catalyst.
8. Remove the exhaust manifold and three way catalyst assembly and gasket. Discard the gasket.
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Monday, March 30th, 2020 AT 3:17 AM
Tiny
HARRY P
  • MECHANIC
  • 2,292 POSTS
Roy is correct about the law and emissions/smog stuff. I would add though that if you're not sure about it being a clogged catalytic converter, you should test it out by simply removing the first oxygen sensor (right under the hood in front of the engine on the exhaust manifold). When a cat gets clogged up, it stops allowing the exhaust out of the system. This creates back pressure, which causes performance issues and eventually stalling the engine. If you take the oxygen sensor out, that gives the exhaust somewhere to escape. Sure, the car will be loud, but if the cat is the issue you'll notice immediately that the car runs longer before having issues with back pressure. I'm attaching an engine diagram showing you where the sensor is. You'll need a 7/8 inch oxygen sensor socket and a ratchet.
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Monday, March 30th, 2020 AT 5:56 AM

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