Catalytic Converter: Service and Repair

Catalytic Converter Replacement (V6) (3.8L)

Removal Procedure





Note: The catalytic converter is serviced by replacing the entire assembly. Always replace the gaskets at the front and rear flanges when servicing the catalytic converter. Never install the original gasket.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Disconnect the heated oxygen sensor (HO2S) electrical connector.
3. Remove the exhaust manifold pipe stud nuts (2).
4. Remove the exhaust manifold pipe gasket (1).
5. Support the exhaust system.




6. Remove the catalytic converter nuts.




7. Remove the catalytic converter hangers.
8. Remove the catalytic converter.
9. Remove the catalytic converter gasket.
10. Clean and inspect the exhaust manifold and the exhaust pipe gasket mating surfaces.
11. Remove the HO2S, if required. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (Service and Repair).

Installation Procedure




1. Install the HO2S, if required. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (Service and Repair).

Caution: Refer to Catalytic Converter Movement Caution (Technician Safety Information).

2. Install a new gasket to the exhaust pipe studs.
3. Install and support the catalytic converter.

Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the catalytic converter nuts.

Tighten the nuts to 60 Nm (44 lb ft).




5. Install a new exhaust manifold pipe gasket (1).
6. Install the exhaust manifold pipe stud nuts (2).

Tighten the nuts to 35 Nm (26 lb ft).




7. Install the catalytic converter hangers.
8. Remove the support from the exhaust system.
9. Connect the HO2S electrical connector.
10. Lower the vehicle.
11. Inspect the exhaust system for leaks and possible underbody contact.