How to Install a 2006 Honda Element Catalytic Converter

In 2003, Honda released an all-new crossover vehicle into the automotive realm: the Element. This compact crossover featured an unorthodox body shape, and had interior conveniences that combined elements of an SUV and pickup truck. The 2006 Element came standard with a 156-horsepower, 2.4-liter four-cylinder engine and used a catalytic converter to keep harmful emissions under control. Replacing the catalytic converter on the 2006 Element requires transferring the heat shields.

Instructions

Removal

1

Lift the front of the Element with a floor jack and slide jack stands under its subframe. Lower the vehicle onto the jack stands. Crawl under the front of the vehicle until you have a clear view of the catalytic converter-and-front pipe assembly.

2

Find the air-fuel sensor, the oxygen sensor attached to the front pipe, just in front of the catalytic converter. Unplug its wiring harness from the Elements harness, pull its wiring from the bracket and remove the sensor, using a ratchet and oxygen sensor socket. Repeat this step to remove the heated oxygen sensor the sensor screwed into the center of the oxygen sensor.

3

Remove the two bolts securing the rear of the catalytic converter to the mid-pipe using a ratchet and socket. Save the spring that goes around each bolt for reuse. Repeat this step to remove the bolts securing the front pipe to the exhaust manifold.

4

Pull the front of the front pipe downward, then pull the pipe forward to remove the catalytic converters flange from the mid-pipe. Remove the front pipe-and-catalytic converter assembly from the vehicle.

5

Unfasten the four bolts securing the heat shield to the catalytic converter using a ratchet and socket, and pull the heat shield from the cat. Remove the three nuts securing the heat shield to the front pipe. Remove the heat shield from the front pipe; the front pipes heat shield has four components -- two heat shield halves and two collars -- so pay close attention to its disassembly so you can reassemble it in the same manner.

Installation

6

Align the bolt holes on the catalytic converter heat shield with the bolt holes in the cat. Hand-thread the heat shield bolts, then snug them with a ratchet and socket.

7

Install the two halves of the front pipe heat shield and the collars onto the front pipe in the reverse manner done when you disassembled it. When correctly assembled, the front-most end of the front pipe should be assembled from the passengers side to the drivers side as follows: heat shield, collar, front pipe, collar, then heat shield. Hand-thread the three heat-shield retaining nuts, then snug them with a ratchet and socket.

8

Slide new doughnut gaskets into the flanges on both ends of the front pipe-and-catalytic converter assembly.

9

Lift the new front pipe-and-catalytic converter assembly into place in the exhaust system, and hand-thread the four bolt and spring fasteners to secure it into place.

10

Tighten the catalytic converter-to-mid-pipe fasteners in small increments, alternating from side to side until you reach a final torque value of 16 foot-pounds, using a torque wrench and socket. Repeat this step to tighten the front pipe-to-exhaust manifold fasteners.

11

Apply a thin coat of an anti-seize compound to the threads of the air-fuel sensor and heated oxygen sensor. Hand-thread the air-fuel sensor into the hole in front of the cat, and the heated oxygen sensor into the hole in the center of the cat, then torque both sensors to 33 foot-pounds using a torque wrench and oxygen sensor socket. Plug both sensors into their respective wiring harnesses on the Element.

12

Raise the vehicle off the jack stands and remove the stands. Lower the Element to the ground.