ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Catalytic Converter

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The catalytic converter is an emission control device added to the exhaust system to reduce the emission of hydrocarbon and carbon monoxide pollutants. Periodic maintenance of the exhaust system is not required, however, if the vehicle is raised for other service, it is advisable to check the general condition of the catalytic converter, pipes and mufflers. Check the exhaust system hangers for damage and deterioration. Replace any hardware if necessary. System damage may occur if there are broken hangers.

REMOVAL & INSTALLATION



See Figures 1 and 2



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Fig. Fig. 1: Rear of the catalytic converter is supported by a hanger-2.2L gasoline engine shown



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Fig. Fig. 2: Exhaust pipe to catalytic converter-2.2L gasoline engine shown

Safety glasses should be worn at all times when working on or near the exhaust system. Older exhaust systems will almost always be covered with loose rust particles which will shower you when disturbed. These particles are more than a nuisance and could injure your eye.

  1. Raise and support the front of the truck safely using jackstands.
  2.  
  3. Spray all fasteners which are to be disconnected using a penetrating oil.
  4.  
  5. Remove the catalytic converter-to-muffler bolts and separate the muffler from the converter.
  6.  

The connection between the converter and the muffler is usually a ball joint type, which can be easily separated.

  1. Remove the catalytic converter-to-front pipe clamp nuts and move the clamp forward.
  2.  
  3. Remove the converter-to-mounting bracket bolts, then twist the converter to separate it from the front pipe.
  4.  
  5. Inspect the condition of the catalytic converter for physical damage, replace it, if necessary.
  6.  

When installing the catalytic converter, be sure that it is installed with adequate clearance from the floor pan, to prevent overheating of the vehicle floor.

  1. Align the components and reverse the removal procedures.
  2.  

Be sure to use a sealing compound, such as 1051249 or equivalent, at the slip joint connection.

  1. Tighten the fasteners taking care not to damage the pipe sealing surfaces when tightening the retaining clamps.
  2.  
  3. Remove the jackstands and carefully lower the truck.
  4.  
  5. Start the engine and check for exhaust leaks.
  6.  

 
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