Catalytic Converter: Service and Repair

Catalytic Converter Replacement (3.8L)

Removal Procedure

Important: The three-way catalytic converter is serviced by replacing the entire assembly. Always replace the gaskets at the front and rear flanges when servicing the three-way catalytic converter assembly. Never reinstall the original gasket.





1. Raise and suitably support the vehicle.
2. Disconnect the heated oxygen sensor wiring harness connector and retainers.

Notice: Refer to Catalytic Converter Movement Notice in Service Precautions.

3. Suitably support the exhaust system.
4. Remove the catalytic converter bolts.
5. Remove the catalytic converter gasket.





6. Remove the exhaust manifold pipe stud nuts.
7. Remove the three-way catalytic converter.
8. Remove the exhaust manifold pipe gasket at the exhaust manifold pipe studs.





9. Remove the heated oxygen sensor.

Installation Procedure





1. Install the heated oxygen sensor.





2. Install a new exhaust manifold pipe gasket to the exhaust manifold pipe studs.

Notice: Refer to Catalytic Converter Movement Notice in Service Precautions.

3. Install and support the three-way catalytic converter.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the exhaust manifold pipe stud nuts.
- Tighten the exhaust manifold pipe stud nuts to 35 Nm (26 ft. lbs.).





5. Install the catalytic converter gasket.
6. Install the catalytic converter bolts.
- Tighten the catalytic converter bolts to 45 Nm (33 ft. lbs.).
7. Connect the heated oxygen sensor wiring harness connector and retainers.
8. Remove the support from the exhaust system.
9. Inspect the exhaust system for leaks and underbody contact.
10. Lower the vehicle.