Catalytic Converter Removal and Installation: Removal

WARNING: This page is about a different car, the 2005 Suzuki Reno and 2005 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect the negative battery cable.
Disconnect the oxygen sensor electrical connector.
Remove the exhaust manifold cover with the bolts.

Fig 1: Removing Exhaust Manifold Cover
Courtesy of SUZUKI OF AMERICA CORP.
Remove the catalytic converter upper flange nuts.
NOTE: The nuts and the stud may unscrew as a unit because of the high temperature associated with the exhaust manifold, but they can be reused as such.

Fig 2: Removing Catalytic Converter Upper Flange Nuts
Courtesy of SUZUKI OF AMERICA CORP.
Remove the exhaust front pipe mounting bracket bolt.
Remove the nuts from the exhaust front pipe-to-catalytic converter flange.
Remove the catalytic converter and the gasket.
Clean the sealing surfaces on the exhaust front pipe flange and the exhaust manifold.
Check the exhaust front pipe and the exhaust manifold for holes, damage, open seams or other deterioration which could permit exhaust fumes to seep into the passenger compartment.

Fig 3: Removing Nuts From Exhaust Front Pipe-To-Catalytic Converter Flange
Courtesy of SUZUKI OF AMERICA CORP.