Catalytic Converter: Service and Repair

Catalytic Converter Replacement (4WD)

Removal Procedure

Caution: Refer to Exhaust Service Caution in Service Precautions.

Caution: Refer to Protective Goggles and Glove Caution in Service Precautions.





1. Remove the right torsion bar.
2. Disconnect the Heated Oxygen Sensor (HO2S) at the sensor pigtail (3).
3. Remove the H02S if replacement is necessary.





4. Remove the nuts securing the muffler to the catalytic converter.
5. Position the muffler rearward enough to allow the studs located in the front to clear the catalytic converter pipe flange.





6. Remove the 3 nuts attaching the catalytic converter to the exhaust manifold.
7. Lower the catalytic converter from the vehicle.





8. Remove the exhaust manifold seal from the exhaust manifold flange. Discard the seal.

Installation Procedure





1. Install the NEW seal to the exhaust manifold flange.






Notice: Refer to Exhaust System Inspection Notice in Service Precautions.

2. Position the catalytic converter to the exhaust manifold.
3. Install the 3 nuts attaching the catalytic converter to the exhaust manifold. Do not tighten at this time.





4. Align the catalytic converter with the studs located in the front of the muffler.

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the 2 nuts securing the muffler to the catalytic converter.
5.1. Tighten the muffler nuts by hand until each contacts the metal flange.
5.2. Tighten the muffler nuts to 45 Nm (33 ft. lbs.).
5.3. Tighten the catalytic converter nuts previously installed in step 3 to 50 Nm (37 ft. lbs.).





6. Install the H02S if previously removed.
7. Connect the H02S at the sensor pigtail (3).
8. Install the right torsion bar.