Cheapest Catalytic Converter Fix - Pontiac G6 Forum
Pontiac G6 Forum Pontiac G6 Forum

» Auto Insurance
» Featured Product
Wheel & Tire Center

Go Back   Pontiac G6 Forum > Technical Discussion & Modifications > Problems and Solutions
Register Home Forums Active Topics Photo Gallery Garage Blogs Search Today's Posts Mark Forums Read Auto Escrow

G6OwnersClub.com is the premier Pontiac G6 Forum on the internet. Registered Users do not see the above ads.
Reply
 
Thread Tools Display Modes
Old 01-02-2011, 09:58 PM   #1
tracer0351
Junior Member
 
tracer0351's Avatar
 
Join Date: Jan 2011
Posts: 2
Gallery: 0
tracer0351 is on a distinguished road
Cheapest Catalytic Converter Fix

I, like many other G6 owners, encountered the problem of a failing catalytic converter and unfortunately, I did not discover this until after the 8yr/80,000 mile warranty on the catalytic. However, I fixed the problem on my own for less than $10 and only a couple hours of my time. I thought I would share with everyone my dirty little tricks. This was done on a 2007 G6 2.4 Liter

The quick version -
Hollow out the cat and create a cel eliminator using two 18mm spark plug non-foulers for the rear O2 sensor. The more detailed version is below for those who need more info.

Because the cat is part of the exhaust manifold, there is no way to make a universal fit, and the replacement is around $450. There have been many complaints about this, and for those of you who are not under warranty, cannot afford a new cat or nice headers, here is what I did:

What you will need:

1/2" sockets, deep and shallow
3" extension
"Universal Joint Sockets"
1/2" Drill bit

One package of 18mm Spark plug Non-Foulers (you may have to order them from your local parts shop, they are not that common anymore, be sure to get the 18mm NOT 14mm) One pack is about $9. See attached pictures for more details on these.


1. Remove Catalytic converter, starting at the exhaust manifold. By freeing up the manifold first, you can get to the three studs at the back of the catalytic much easier. (It's still tight, but manageable)

2. Once the cat is removed, unscrew the front O2 sensor from the cat, this is important, as you will see in the next step.

3. From the back of the cat, take a punch and a hammer and clean out all of the guts. If that O2 sensor is still in, there is a chance you could hit it with the punch and that's not good. Keep in mind, hollowing out the cat will ensure that you DO NOT pass emissions if required in your state.

4. Once you have cleaned it all out, replace the front O2 sensor.


Part II


Those spark plug non-foulers are simply used as a spacer for the rear O2 sensor to "help" it get the proper emissions readings so you do not have a check engine light.


1. Drill out the center of ONE of the non-foulers using a 1/2" drill bit. This creates enough room for the O2 sensor to be seated properly.

2. Screw the drilled out non-fouler into (on top of) the other non-fouler.

3. Be sure to put the gasket on the bottom non-fouler before crawling back under the car.


ReInstallation


1. Remember all of your gaskets and a little high-temp silicone if you have any available. I found it easiest to connect the rear of the catalytic before setting it on the manifold studs. That gave me flexibility to get those tight studs lined up. (It's probably no problem if you have 2 people, but I was alone)

2. Once everything is cinched down at the manifold and the rear, disconnect the negative battery cable, then unscrew the REAR O2 sensor, located just behind where the catalytic connects with the exhaust system.

3. I couldn't reach the plug in for the sensor so I had to fight twisting wires a little bit, but that was easier than trying to reach a plug I couldn't put my pinky on if I wanted to. I left the O2 sensor plugged in while I unscrewed it from the pipe.

4. Once the sensor is free, screw your non-foulers onto the O2 sensor.

5. Screw the O2 sensor with the non-foulers attached back into the pipe.

6. Reconnect the negative battery cable and you are all set!


Remember, this is not in compliance with emissions. Your car may run a little louder, but it is barely noticeable.


I got all of my lost power back as well as my gas mileage! And no check engine light thanks to the non-fouler trick!

Hope the post wasn't too much, just thought it might help a few more suffering from the crappy catalytics they used on these cars.
[/COLOR][/B]
Attached Thumbnails
Click image for larger version

Name:	dsc00062small4ik.jpg
Views:	723
Size:	45.7 KB
ID:	1657   Click image for larger version

Name:	dsc00061small28ie.jpg
Views:	676
Size:	46.6 KB
ID:	1658   Click image for larger version

Name:	dsc00070small1pm.jpg
Views:	668
Size:	50.7 KB
ID:	1659   Click image for larger version

Name:	dsc00078small5cm.jpg
Views:	635
Size:	46.4 KB
ID:	1660   Click image for larger version

Name:	dsc00080small2nv.jpg
Views:	722
Size:	69.3 KB
ID:	1661  

tracer0351 is offline   Reply With Quote
Sponsored Links
Advertisement
 
Old 06-19-2012, 08:52 PM   #2
Chongjr
Junior Member
 
Join Date: Jun 2012
Posts: 6
Gallery: 0
Chongjr is on a distinguished road
Hey man thank u so much for this my wife's g6 just started having problems found out its the cat. This helps a bunch thank you .... Do u happen to have a video on how it sounds ... She is worried that it will get to loud .... Unknow this post is like a year old
Chongjr is offline   Reply With Quote
Old 06-19-2012, 09:15 PM   #3
gmitch23
Keep it factory baby!
 
gmitch23's Avatar
 
Join Date: Aug 2010
Location: Oklahoma
Age: 33
Posts: 100
Gallery: 0
gmitch23 is on a distinguished road
Did you not get an extended warranty from gm specifically for the cat?? Suppose to be for 120k or ten years

Sent from my SAMSUNG-SGH-I717 using AutoGuide.Com Free App
gmitch23 is offline   Reply With Quote
Old 06-20-2012, 06:50 AM   #4
Chongjr
Junior Member
 
Join Date: Jun 2012
Posts: 6
Gallery: 0
Chongjr is on a distinguished road
I'm not sure I got this through a private seller (old couple) .... I am taking it to the dealer today to see .... I have been reading an apparently gm gave u a 8tr/80000 mile emissions Warrenty do hopefully that will cover it
Chongjr is offline   Reply With Quote
Old 06-20-2012, 10:18 AM   #5
slls
Senior Member
 
Join Date: Dec 2005
Posts: 528
Gallery: 0
slls is on a distinguished road
BTW That bypass is a $10 K fine if your caught.
slls is offline   Reply With Quote
Old 07-04-2012, 05:37 PM   #6
Stassylea
Junior Member
 
Join Date: Jul 2012
Posts: 1
Gallery: 0
Stassylea is on a distinguished road
Uh...?

Quote:
Originally Posted by Chongjr View Post
I'm not sure I got this through a private seller (old couple) .... I am taking it to the dealer today to see .... I have been reading an apparently gm gave u a 8tr/80000 mile emissions Warrenty do hopefully that will cover it
How do I go about finding out if I have the warranty? I'm having the same problem with my car. I'm clueless, and need all the help I can get.
Stassylea is offline   Reply With Quote
Old 07-05-2012, 06:24 AM   #7
P Magic
Senior Member
 
P Magic's Avatar
 
Join Date: Nov 2010
Location: New Baltimore, Michigan
Age: 35
Posts: 411
Gallery: 6
P Magic is on a distinguished road
Call your local GM dealership. They can run your VIN# and see what warranties you have and any open recalls.
__________________

IT ONLY LOOKS FAST!!!

My Progression Thread
P Magic is offline   Reply With Quote
Old 07-05-2012, 12:48 PM   #8
greenman
OOBER SUPER MEMBER
 
Join Date: Jul 2011
Posts: 2,208
Gallery: 0
greenman is on a distinguished road
Quote:
Originally Posted by P Magic View Post
Call your local GM dealership. They can run your VIN# and see what warranties you have and any open recalls.
That's good advice.

All cars made since '95 have 8 year, 80,000 mile emissions warranty on the cat/s. There is a GM extension to that warranty for some G6 VINs to 10 years/ 120,000 miles (IIRC).
greenman is offline   Reply With Quote
Old 07-06-2012, 06:23 PM   #9
Chongjr
Junior Member
 
Join Date: Jun 2012
Posts: 6
Gallery: 0
Chongjr is on a distinguished road
Yea I just called my local gm dealership they checked and took car of it no charge had it back to me same day
Chongjr is offline   Reply With Quote
Old 06-28-2013, 12:50 PM   #10
laureney
Junior Member
 
Join Date: Jun 2013
Posts: 1
Gallery: 0
laureney is on a distinguished road
cat probs

my catalytic converter needs replacing, its an 06 pontiac g6 gt does anyone know if gm is covering this? i have 116,000 k on the car and just replaced the engine cant do another expensive repair
laureney is offline   Reply With Quote
Old 06-28-2013, 03:55 PM   #11
greenman
OOBER SUPER MEMBER
 
Join Date: Jul 2011
Posts: 2,208
Gallery: 0
greenman is on a distinguished road
Quote:
Originally Posted by laureney View Post
my catalytic converter needs replacing, its an 06 pontiac g6 gt does anyone know if gm is covering this? i have 116,000 k on the car and just replaced the engine cant do another expensive repair
Call GM CS or a dealer with your VIN & they'll tell you. Some VINs were extended to 120K. Also, states have different laws. Some require higher performance (more expensive) cats. Any muffler shop can give you details.
greenman is offline   Reply With Quote
Sponsored Links
Advertisement
 
Reply

  Pontiac G6 Forum > Technical Discussion & Modifications > Problems and Solutions


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Catalytic converter issue Martinacan Problems and Solutions 33 07-29-2010 01:27 PM
Is my G6 catalytic converter bolt on or weld on? gringogigante Problems and Solutions 12 10-07-2009 02:18 PM
07' g6 output converter JLAFRAY Car Audio, Video and Security 1 09-25-2009 08:52 PM
Best dvd and video to iphone converter stone2007 G6 Buyer's Guide/General Information 0 10-21-2008 06:34 AM
Line Out Converter,neccasary?? Wolfblood Car Audio, Video and Security 2 09-24-2008 11:43 AM

Powered by vBadvanced CMPS v3.2.2

All times are GMT -6. The time now is 01:40 PM.



Powered by vBulletin® Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Garage Plus vBulletin Plugins by Drive Thru Online, Inc.
© AutoGuide
Inactive Reminders By Icora Web Design