Service Procedure

Catalytic Converter Inspection

Begin the inspection by reviewing the condition described by the customer. Refer to "Description and Operation," SI document, to help you determine the correct symptom diagnostic procedure when a malfunction exists. It will also help you determine if the condition described by the customer is normal operation. Refer to "Symptoms [horbar] Engine Exhaust", in order to identify the correct procedure for diagnosing the system. If a new catalytic converter is required, refer to the service procedure in this bulletin. If a catalytic converter is not required, submit a claim for inspecting the catalytic converter only. Refer to the Claim Information section of this bulletin.

Catalytic Converter Replacement for W-Series Vehicles Equipped With 3.4L (LA1) and 3.8L (L36) Engines

Tools Required

J 39194 Oxygen Sensor Wrench

Important:
The 3-way catalytic converter is serviced by replacing the entire assembly. Always replace the gaskets at the front and rear flanges when servicing the 3-way catalytic converter assembly. Never reinstall the original gasket.

1. Raise and support the vehicle.

2. Disconnect the heated oxygen sensor wiring harness connector.

A. Remove the heated oxygen sensor electrical connector retaining tab from the electrical harness connector.

B. Disconnect the heated oxygen sensor connector from the electrical harness connector.

3. Remove the exhaust manifold pipe nuts and studs.





4. Remove the catalytic converter bolts.

5. Remove the catalytic converter hangers.

6. Remove the 3-way catalytic converter.

Notice:
The Heated Oxygen Sensor (HO2S) and the Oxygen Sensor use a permanently attached pigtail and connector. Do not remove this pigtail from the Heated Oxygen Sensor. Damage or the removal of the pigtail or the connector could affect the proper operation of the sensor. Take care when handling the HO2S and the 02S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Also avoid using cleaning solvents of any type. Do not drop the HO2S or the 02S. Do not roughly handle the HO2S or the O2S.

7. Remove the heated oxygen sensor from the catalytic converter assembly using J39194 tool.

8. Install the heated oxygen sensor to the new catalytic converter assembly using J39194 tool.

Tighten

Use the J 39194 tool to tighten the oxygen sensor to 41 Nm (30 lb ft).





9. Remove the catalytic converter gasket from the catalytic converter mating surfaces.





10. Install a new exhaust manifold pipe gasket.

- If the vehicle is equipped with a 3.4L (LA1) engine, install the metal ring gasket (P/N 24505057) into the catalytic converter assembly flange.

- If vehicle is equipped with a 3.8L (L36) engine, remove the exhaust manifold pipe gasket at the exhaust manifold pipe flange.

11. Install the exhaust manifold pipe studs.

- If the vehicle is equipped with a 3.8L (L36) engine, install a new exhaust manifold pipe gasket (P/N 15286606) to the exhaust manifold pipe studs.

- If the vehicle is equipped with a 3.4L (LA1) engine, proceed to step 12.

12. Install the 3-way catalytic converter (P/N 10343185) for 3.4L (LA1) and (P/N 10343187) for 3.8L (L36).





13. Install the exhaust manifold pipe stud nuts.

Tighten

Tighten the exhaust manifold pipe stud nuts to 35 Nm (26 lb-ft) for the 3.8L (L36) engine and 56 Nm (41 lb-ft) for the 3.4L (LA1) engine.

Notice:
To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

14. Install a new catalytic converter gasket, P/N 10328740.

Install the catalytic converter bolts.

Tighten

Tighten catalytic converter bolts to 60 N.m (44 lb ft).

15. Connect the heated oxygen sensor to the electrical connector and install the retaining tab to the electrical tab.

16. Install the catalytic converter hangers.

17. Lower the vehicle.

18. Inspect the exhaust system for leaks.