How to Replace Exhaust Manifold with Catalytic Converter 96-00 Honda Civic
Difficulty: Advanced · About 240 min · Honda Civic
Replace the exhaust manifold and catalytic converter on a 1996–2000 Honda Civic with a compliant replacement, using new gaskets and keeping oxygen-sensor wiring and hot exhaust components protected.
Tools you will need
- 12mm Socket
- 13mm Socket
- A Piece of Pipe (for leverage)
- Torque Wrench
- 14mm Socket
- Rust Penetrant
- Jack Stands
- Flat Blade Screwdriver
- 7/8 Inch Socket
- O2 Sensor Socket
- 10mm Socket
- Ratchet
- Floor Jack
- Wire Cutters
- 11mm Socket
Parts and supplies
- Compliant catalytic-converter and exhaust-manifold assembly
- Exhaust gaskets
- Oxygen sensors
Steps
- Allow the exhaust to cool and remove the sensors
Work only after the exhaust is fully cool and the vehicle is safely supported. Disconnect the oxygen-sensor harnesses, label their positions, and remove the sensors with the correct socket; avoid cutting the wires if a sensor is seized.
- Unfasten the manifold and converter support
Remove the heat-shield fasteners and manifold nuts, then unbolt the converter support brackets. Keep the sensor wiring clear and apply penetrant to corroded hardware rather than forcing a fastener until it breaks.
- Remove the catalytic converter
Raise and support the vehicle at approved points, remove the converter-to-exhaust fasteners, and guide the assembly out without damaging nearby lines or wiring. Keep the old gaskets for comparison, then discard them.
- Prepare the replacement assembly
Transfer any required heat shield or support bracket to the compliant replacement part. Clean the mating surfaces without gouging them and install new exhaust gaskets in the correct orientation.
- Install the manifold and converter
Position the assembly on its studs and align the exhaust flange without forcing it. Start all fasteners by hand, tighten the manifold and support hardware in the specified sequence to vehicle torque, and reinstall the heat shield.
- Reconnect sensors and inspect for leaks
Reinstall each oxygen sensor in its original position and reconnect its harness to the proper clips. Lower the vehicle, start the engine, and check for exhaust leaks and warning lights after the system is safely assembled.
Check your vehicle’s repair manual for exact specifications and fit.