OEM 2005 Chevrolet Malibu Catalytic Converter

2005 Chevrolet Malibu Parts Questions & Experts Answers

• Q: How to replace the front catalytic converter on a 3.5L engine on 2005 Chevrolet Malibu?

  A: Replace the front Catalytic Converter on a 3.5l engine through this step-by-step process: first unfasten the front Catalytic Converter nuts at the Exhaust Manifold using the heated Oxygen Sensor wrench (J 39194-B). Detach the rear heated Oxygen Sensor (HO2S) connector position assurance (CPA) retainer while being cautious not to damage permanent pigtails or connector assemblies before disconnecting the rear ho2s electrical connector. The process should be repeated for the front ho2s by removing both its cpa retainer and electrical connector. Start removing the front and rear ho2s with the same wrench before proceeding to remove the rear Catalytic Converter bolts from the Exhaust Manifold. Discard the gaskets at this time. Start by removing the rear Catalytic Converter followed by removing the front Catalytic Converter to rear Catalytic Converter nuts before finishing with the front Catalytic Converter itself while getting rid of both gaskets. Verify that the flange between the Catalytic Converter and Exhaust Manifold passes the 0.7 mm (0.028 inch) service requirement. The front Catalytic Converter installation requires new front gaskets first followed by installation of the front Catalytic Converter along with new gaskets for the rear Catalytic Converter studs that precede rear Catalytic Converter installation. Start by fastening the Exhaust Manifold nuts to the rear Catalytic Converter with a torque of 31 nm (23 ft. Lbs.). Then proceed to tighten the front Catalytic Converter to the rear Catalytic Converter nuts to 31 nm (23 ft. Lbs.). Use the wrench to reinstall both front and rear ho2s sensors while securing them at 42 nm (31 ft. Lbs.) before connecting and retaining the electric cables and cpa units for the ho2s sensors. Reinstall the Muffler assembly and front Catalytic Converter Exhaust Manifold nuts at 31 nm (23 ft. Lbs.). Start the engine to inspect for exhaust leaks.