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Replace cat converter on 240 200 1989

It can be done in your driveway if you have the tools (Jackstands, grinder w/ cutting wheel, ratchet/sockets/box end wrenches) and do not mind getting filthy.

1) Before you buy a replacement-jack up the car and place jackstands and examine the existing Cat front flange to Down pipe connection. Is the downpipe flange good? If not plan on replacing the downpipe as well because you will trash a marginal flange during installation.

2) If the downpipe flange is good. Then look at the cat and exit pipe. Measure the distance from the Cat forward flange to the exit pipe and add 1 1/2 to 2 inches. Look at the type of clamp used to secure the cat pipe to the pipe to the resonator. If its U clamp plan on trashing it and replace with circular type.

3) Since you are trashing the cat you don't care about the cat to downpipe bolts so cut them off w/ a grinder and punch out with a hammer and punch. FCP and others sell the new bolts and nuts for $5 a set-cheap at any price!
Remove the O2 sensor if installed in the cat. It sometimes comes free with a open end wrench but you can get/rent a O2 socket that makes it easier.

4) Cut bolt on old rear pipe clamp. Take a propane torch and heta up the connection and smack it w/ a hammer. Wear gloves and try and turn the cat pipe. If it won't come loose try using a screwdriver or drift to open the seam between the cat pipe and the rear pipe. Once you get it off take a file and clean the inside of the rear pipe.

5) Clean downpipe flange face and install gasket and 1 bolt. Install clamp on rear pipe. Line up cat exit pipe with rear pipe and slide it in. Line up cat front flange to gasket/bolt and hang it on the bolt and install the nut witha few spins.

6)Install remainder of bolts (2) and wrench tighten them. Check the rear pipe clamp fit and leave it loose.

7) Tighten front flange bolts, remove O2 plug and install O2 sensor if needed.
Tighten rear pipe clamp.

8) Have a beer, you earned it.







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©Jarrod Stenberg 1997-2022. All material except where indicated.


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