Re: How difficult to replace catalyst converter - Saab 9-5 Bulletin Board - Saabnet.com
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Re: How difficult to replace catalyst converter
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Posted by Gene N [Email] (#1094) [Profile/Gallery] (more from Gene N) on Tue, 15 Mar 2016 11:18:53 Share Post by Email
In Reply to: How difficult to replace catalyst converter, Gordon in CA, Tue, 15 Mar 2016 03:39:20
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On paper (or, on-screen), it would seem to be a relatively easy task. Remove the intake tubes to get at some bolts. Disconnect the two connectors from the O2 sensors. Remove three bolts on the turbo, two bolts on the flex pipe, one or two bolts on some support straps, drop the pipe and pull it out. Move the O2 sensors to the new down pipe/catalytic converter and put the pipe back in the way it came out. Reverse the rest of the procedure and you are done.

If this were 2003, the procedure would be, in fact, relatively easy. The reality in 2016 is that the nuts and studs have become quite cozy together in the last 13 years, and they are not going to be separated without liberal and repeated application of PB-Blaster or similar concoction over a period of days. You may need to heat each stud to a cherry red color and apply enough torque to your wrench to ALMOST snap the stud. Oh, and don't forget to swear to your favorite deity when your knuckles are bleeding and there are rust flakes in your eyes.

When possible, I try to replace the entire exhaust system at one time, cutting the old pipes out with a reciprocating saw, but sometimes that isn't practical.

I hope this answers your question.

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