how to fix a faulty catalytic converter on my Toyota Corolla E210 (2019-2024)?

Solution

1. Preparation

• Gather tools: OBD-II scanner, socket set, torque wrench, jack and jack stands, exhaust pipe cutter, and safety goggles.
• Ensure the vehicle is parked on a level surface and the engine is cool.
• Disconnect the battery to ensure safety during the repair.

2. Remove the Faulty Catalytic Converter

• 2.1. Raise the Vehicle
  • Use a jack to lift the vehicle and secure it on jack stands.
• 2.2. Locate the Catalytic Converter
  • Identify the position of the catalytic converter along the exhaust system, typically between the exhaust manifold and the muffler.
• 2.3. Disconnect Exhaust Components
  • Use a socket set to remove the bolts securing the catalytic converter to the exhaust manifold and the connecting pipe. Be cautious of rusted bolts; apply penetrating oil if necessary.
• 2.4. Cut the Exhaust Pipe (if necessary)
  • If the catalytic converter is welded to the exhaust pipe, use an exhaust pipe cutter to remove it.
• 2.5. Remove the Catalytic Converter
  • Carefully take out the old catalytic converter from the exhaust system.

3. Install the New Catalytic Converter

• 3.1. Position the New Converter
  • Place the new catalytic converter in position, ensuring it aligns with existing exhaust components.
• 3.2. Secure the Converter
  • If using bolts, hand-tighten the bolts to the exhaust manifold and the connecting pipe, then torque them to the manufacturer's specifications (typically around 30-40 lb-ft).
• 3.3. Weld (if applicable)
  • If the converter was cut out, weld the new catalytic converter to the exhaust pipe properly to ensure no leaks.

4. Reconnect Battery and Test

• 4.1. Reconnect the Battery
  • Reconnect the negative terminal of the battery.
• 4.2. Clear Error Codes
  • Use the OBD-II scanner to clear any error codes related to the catalytic converter.
• 4.3. Start the Engine
  • Start the vehicle and allow it to idle. Check for any unusual sounds or leaks in the exhaust system.