Question about 2002 Volkswagen Passat

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2002 Passat 1.8Turbo

Need to replace Catalytic Converter. How can you reach the lower bolts to replace. Does alot of other extra's need to be removed

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Hi Sam,

need a special sucket tool

Posted on Jul 06, 2008


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Rear Catalytic Converter 2002 Mercury Sable

The catalytic converter is part of the exhaust system, which is the air running out of your engine. The engine does not need to come out to remove it. Look under your car. Your exhaust pipe comes out the back. Follow the pipe back toward the engine, past your muffler (which is a big box) and you will see a foot-long section of the pipe that is larger than the rest (but still round). That is your catalytic converter.
Sometimes it will be covered by a heat shield (a piece of metal that keeps the extreme heat of the cat. away from everything else.

Step one: Jack the car up and place it on jack stands.
Step two: Let the car cool down a little cause the exhaust is extremely hot and will burn you.
Step three: locate the bolts that hold the catalytic converter onto the other exhaust pipe pieces (this will be easier if you have the new one so you can see how long it actually is.)
Step four: Spray the bolts you need to loose with penetrating oil ($3 at the auto parts store). These bolts are going to be VERY hard to get off because they are rusted and they are used to being hot. If you can use a six point socket, that will keep them from stripping. You can also heat the bolt up with a torch (until it glows orange) and this will make it easier to move. Be careful.
Step five: remove the oxygen sensor that is attached to the catalytic converter. This will just look like wires coming from a cylinder that is sticking into it. Unscrew the cylinder (I recommend an oxygen sensor socket as this bolt is quite difficult too, especially when cold. Don't heat the oxygen sensor with a torch or you could damage it)
Step six: Unbolt the catalytic converter (now that you have sprayed the bolts with penetrating oil and let them sit for a few minutes.
Step seven: Place the new catalytic converter in the old one's place, and do everything in reverse.

The best advice I can give you is be safe, and don't give up. automotive repair is about perseverance as much as know-how. When you come across that bolt that just won't budge, keep working at it and try to think of different ideas (like a breaker bar, or drilling it out with a drill). You can do this job!
I've attached a video that I found. It may be helpful.

Jan 13, 2014 | 2002 Mercury Sable

1 Answer

What are the torque specs for 1996 Buick Century 3.1 L intake manifold?

Front Pipe REMOVAL & INSTALLATION Pipe Without Catalytic Converter
  1. Before removing any component of the exhaust system, always squirt a liquid rust dissolving agent onto the fasteners for ease of removal..
  2. Raise and support the front of the vehicle on jackstands.
  3. Remove the exhaust pipe-to-manifold nuts.
  4. Support the catalytic converter, then disconnect the pipe from the converter. Remove the pipe.
  5. Remove the exhaust gaskets. To install:
  6. Be sure to use all new gaskets when required. Assemble the system, check the clearance and tighten the bolts to about 15-30 ft. lbs. (20-41 Nm). Fig. 1: Front exhaust pipe connection common on vehicles with the catalytic converter not included 86813320.gif

  7. All clamps should be tightened to about 18-25 ft. lbs. (24-34 Nm). Do overtighten the clamps. If pipes become dented they can leak.
Pipe With Catalytic Converter
  1. Before removing any component of the exhaust system, always squirt a liquid rust dissolving agent onto the fasteners for ease of removal.
  2. Raise and support the vehicle.
  3. On some vehicles you will need to remove the brace from the transaxle.
  4. Remove the exhaust pipe nuts from the manifold.
  5. Support the catalytic converter pipe bolts from the rear of the converter.
  6. Lower the catalytic converter/front pipe assembly from the vehicle. To install:
  7. Be sure to use all new gaskets when required.
  8. Attach the new catalytic converter/front pipe assembly to the vehicle. Tighten the pipe to manifold nuts to 20-40 ft. lbs. (27-55 Nm).
  9. Attach the bolts at the rear of the catalytic converter/front pipe. Tighten them to 30-35 ft. lbs. (41-47 Nm).
  10. Connect the brace at the transaxle if removed.
  11. Lower the vehicle. prev.gif next.gif

Dec 18, 2010 | Buick Century Cars & Trucks

1 Answer

I have taken the oil pan bolts out and there is not enough clearance to remove the pan on a 2002 Buick Regal 3800 to replace the gasket. What steps do you suggest next.

Did you remove the catalytic converter, and motor mount? Lots of stuff has to come off to get this pan out. :o(

3.8L Engine
  1. Drain the engine oil.
  2. Remove or disconnect the following:

    Negative battery cable Throttle body air inlet duct Engine mount struts Accessory drive belt
  3. Install an engine support fixture.

    Catalytic converter from the right exhaust manifold Right front wheel Right side splash shield Oil filter and discard A/C compressor bracket and reposition the compressor Power steering oil cooler pipe brackets from the frame Engine mount bracket bolts Lower engine mount nuts Torque converter cover Oil level sensor electrical connector Oil level sensor
  4. Raise the vehicle and place a support under the frame.

    Right side frame bolts and loosen the left side bolts Engine mount and bracket Oil pan

Nov 21, 2010 | 2002 Buick Regal

1 Answer

Catalytic Converter 2002 ford taurus does the engine have to come out or just the axles? what is the best way to replace the Catalytic Converter? I have remove the heat shield and disconnected the pipe,...

SECTION 309-00: Exhaust System 2002 Taurus/Sable Workshop Manual REMOVAL AND INSTALLATION Dual Converter Y-Pipe -3.0L (2V)
Special Tool(s) s2h~us~en~file=st2363a.gif~gen~ref.gif 3 Bar Engine Support
303-290A s2h~us~en~file=st1595a.gif~gen~ref.gif Engine Lifting Brackets (3.0L 2V)
303-050 (T70P-6000) or equivalent Removal
  1. Disconnect the negative battery cable. For additional information, refer to Section 414-01 .
  1. Remove the bolts and engine roll restrictor.
  1. Remove the bolt, ground strap, and nut.
  1. Raise and support the vehicle. For additional information, refer to Section 100-02 .
  1. Remove the splash shield and the air deflector.
  1. Disconnect the catalyst monitor sensor (CMS) electrical connectors.
  1. Remove the nut and position the heat shield out of the way.
  1. Remove the nut.
  1. Remove the nut.
  1. NOTE: Support the exhaust with mechanic's wire.
    Remove the nuts and disconnect the three-way catalytic converter from the dual converter Y-pipe.
  1. Lower the vehicle.
  1. Remove the nuts.
  1. Remove the bolt.
  1. Using the special tools, raise the front of the engine.
  1. Raise the vehicle.
  1. Remove the bolt.
  1. s2h~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: The sharp edges on the converter can cut the CV joint boot. Make sure to protect the half-shaft boot with a suitable covering before removing the converter assembly.
    Remove the dual Y-pipe converter assembly.
  1. Remove the gaskets and, if necessary, the catalyst monitor sensors (CMS).
    • Discard the gaskets.

Nov 03, 2010 | 2002 Ford Taurus

2 Answers

I have an 1998 Chevy Blazer and need to change the catalytic converter, are the flange bolts welded and can i cut them

Catalytic Converter Removal & Installation 2.2L Engine To Remove:
Catalytic converter 2.2L engine gm-03-22-734.gif

  1. Raise and safely support the vehicle.
  2. Disconnect the heated oxygen sensor (HO2S) electrical connector.
  3. Remove the exhaust manifold pipe flange mounting nuts from the catalytic converter.
  4. Remove the catalytic converter flange mounting nuts from the muffler.
  5. Remove the catalytic converter from the muffler.
  6. Remove the catalytic converter from the rear hanger bracket insulator.
  7. Remove the catalytic converter.
  8. Remove the (HO2S) from the catalytic converter.
To Install:
  1. Install the (HO2S) to the catalytic converter.
  2. Install a new gasket and the catalytic converter to the muffler.
  3. Install catalytic converter to the catalytic converter hanger.
  4. Install the catalytic converter flange mounting nuts to the muffler flange.
    • Tighten to 26 ft lbs (35 Nm).
  5. Install the catalytic converter flange mounting nuts to the exhaust manifold pipe flange.
    • Tighten to 26 ft lbs (35 Nm).
  6. Connect the heated oxygen sensor (HO2S) electrical connector.
  7. Lower the vehicle.
------ Catalytic Converter Removal & Installation 4.3L Engine To Remove:
  1. Raise and safely support the vehicle.
  2. Raise and support the transmission.
  3. Remove the transmission support
  4. Disconnect the left and right pre-converter heated oxygen sensor (HO2S) electrical connector.
  5. Disconnect the post-converter (HO2S) connector. Muffler flange and gasket gm-03-43-731.gif

  6. Remove the catalytic converter flange mounting nuts from the muffler.
  7. Remove the catalytic converter from the muffler.
  8. Remove the exhaust manifold flange mounting nuts from the catalytic converter. Catalytic converter 4.3L engine gm-03-43-735.gif

  9. Remove the catalytic converter from the support bracket insulator.
  10. Remove the catalytic converter and gaskets.
  11. Remove the heated oxygen sensor.
To Install:
  1. Install the heated oxygen sensors as needed.
  2. Install a new gasket and the Install the catalytic converter to the support bracket insulator.
  3. Install the catalytic converter to the exhaust manifold flange. Install the mounting nuts.
    • Tighten to 39 ft lbs (53 Nm).
  4. Using a new flange gasket, install the catalytic converter to the muffler. Install the mounting nuts.
    • Tighten to 30 ft lbs (40 Nm).
  5. Connect the left and right pre-converter heated oxygen sensor (HO2S) electrical connectors.
  6. Connect the post-converter (HO2S) electrical connector.
  7. Install the transmission support.
  8. Lower the transmission.
  9. Lower the vehicle.
prev.gif next.gif ---
It looks like you can cut them and replace them with new bolts and nuts.prev.gif next.gif

Sep 05, 2010 | 1998 Chevrolet Blazer

1 Answer

Exhaust emission warning lamp is on, in my 2002 passat?

either your air pump is bad or you need a catalytic converter the only way to be sure is hook it to a scanner and watch the info but it is one of those two

May 05, 2010 | 2002 Volkswagen Passat

2 Answers

Cadillac converter needs to be replaced

Torque converter?
Catalytic Converter?

Catalytic converter:
Take vehicle to a local muffler shop (not a national chain). They will do a professional job and the cost is much lower than other places.

Sep 30, 2009 | 2001 Volkswagen Passat

1 Answer

Catalytic converter

HI, this guide will help you with this replacement.

Step1 Lift your jeep. Unfortunately, the catalytic convertermag-glass_10x10.gif sits about midway down the length of your jeep, so lifting one end or the other will not do. Ramps are your best bet to get you within reach of the parts when working from home. Luckily, this is usually the hardest part of this repair. Step2 Be patient with the bolts, as they are often hard to remove due to size and awkward placement. You may have to drill or saw bolts to remove them. With this in mind, you should pick up new bolts, nuts and seals for your replacement project. Step3 Buy a catalytic converter specific to your jeep to avoid extra work. A generic part must be welded into the jeep, while a vehicle-specific model comes pre-welded to the proper pipes for easy bolt-on installation. Step4 Remove the 02 sensor (with an O2 wrench) before unbolting the catalytic converter. Then, you should remove the pipe connecting the sensor to the converter. Depending on your exhaust system, you may have to remove more pipes before you unbolt the converter from the muffler. Step5 Replace the old catalytic converter with a new one. This should be the easy part, as you simply bolt the new part in place. Step6 Reattach the exhaust pipesmag-glass_10x10.gif and 02 sensor, and the basic job is done. Make sure you replace any cracked or rusty pipes while you have the exhaust system apart.

  • Catalytic converters often fall under a separate emissions warranty that lasts at least 7 years and 160,000 miles. Even if your car is out of its regular warranty, but it is a newer model, ask your dealer to replace the part for you free of charge.
  • Rent the O2 wrench or socket if you do not own one. Most auto parts stores carry this tool for rentals.
  • In many states, older (vintage) cars do not need a catalytic converter, so you can gut it or remove it completely. No damage will result from running a car without a converter.
  • Due to emissions standards, it is illegal to buy or install used converters.
Please rate and god bless:)

Apr 20, 2009 | 1998 Jeep Wrangler

2 Answers

Underperforming catalist

readings taken downstream (exhaust) with the O2 sensor are telling your computer that the catalytic converter is not doing its job well enough (it is reading too high an exhaust content of carbon monoxide or hydrocarbons) the solution is to replace the catalytic converter assuming the engine and its other management systems are performing healthy ....good luck

Oct 22, 2008 | 2002 Volkswagen Passat

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