Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2002EXPRESS 1/2 TON VAN V6-4.3L VIN WREPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTEMISSION CONTROL SYSTEMSCATALYTIC CONVERTERSERVICE AND REPAIR
2002 Chevrolet Express 1/2 Ton Van V6-4.3L VIN W
Catalytic Converter: Service and Repair
2002 Chevrolet Express 1/2 Ton Van V6-4.3L VIN WSECTION Service and Repair
Catalytic Converter Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting.
2. Disconnect the Heated Oxygen Sensor (H02S) electrical connections from catalytic converter pipe.
3. Remove the transmission support.
Caution: Refer to Exhaust Service Caution in Service Precautions.
Caution: Refer to Protective Goggles and Gloves Caution in Service Precautions.
4. Remove the nuts and the seals retaining the catalytic converter pipe to the exhaust manifolds.
5. Remove the flange nuts from the catalytic pipe to the muffler.
6. Remove the catalytic converter from the vehicle.
7. Remove the oxygen sensors as necessary.
Installation Procedure
1. Install the oxygen sensors as necessary.
2. Position the catalytic pipe to the vehicle.
3. Install the new retaining nuts and gasket to the front of the muffler. Do not tighten the nuts.
Notice: Refer to Fastener Notice in Service Precautions.
4. Install the new seals, the nuts and the exhaust pipe flange to exhaust manifold.
^ Tighten the exhaust pipe flange to exhaust manifold nuts to 65 Nm (48 ft. lbs.).
^ Tighten the catalytic converter to muffler retaining nuts to 48 Nm (35 ft. lbs.).
5. Connect the H02S electrical connections.
6. Install the transmission support.
Notice: Refer to Exhaust System Inspection Notice in Service Precautions.
7. Verify the exhaust system for proper clearance and the alignment of all components.
8. Lower the vehicle.
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting.
2. Disconnect the Heated Oxygen Sensor (H02S) electrical connections from catalytic converter pipe.
3. Remove the transmission support.
Caution: Refer to Exhaust Service Caution in Service Precautions.
Caution: Refer to Protective Goggles and Gloves Caution in Service Precautions.
4. Remove the nuts and the seals retaining the catalytic converter pipe to the exhaust manifolds.
5. Remove the flange nuts from the catalytic pipe to the muffler.
6. Remove the catalytic converter from the vehicle.
7. Remove the oxygen sensors as necessary.
Installation Procedure
1. Install the oxygen sensors as necessary.
2. Position the catalytic pipe to the vehicle.
3. Install the new retaining nuts and gasket to the front of the muffler. Do not tighten the nuts.
Notice: Refer to Fastener Notice in Service Precautions.
4. Install the new seals, the nuts and the exhaust pipe flange to exhaust manifold.
^ Tighten the exhaust pipe flange to exhaust manifold nuts to 65 Nm (48 ft. lbs.).
^ Tighten the catalytic converter to muffler retaining nuts to 48 Nm (35 ft. lbs.).
5. Connect the H02S electrical connections.
6. Install the transmission support.
Notice: Refer to Exhaust System Inspection Notice in Service Precautions.
7. Verify the exhaust system for proper clearance and the alignment of all components.
8. Lower the vehicle.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.