Catalytic Converter: Service and Repair

Catalytic Converter Replacement (4WD)

Removal Procedure
Warning: Refer to Exhaust Service Warning (Exhaust Service Warning).

Warning: Refer to Protective Goggles and Glove Warning (Protective Goggles and Glove Warning).





1. Remove the right torsion bar. Refer to Front Torsion Bar Replacement (Front Torsion Bar Replacement).
2. Disconnect the heated oxygen sensor (HO2S) at the sensor pigtail (3).
3. Remove the HO2S if replacement is necessary. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (Heated Oxygen Sensor Replacement - Sensor 2) for the 2.9L engine or Heated Oxygen Sensor Replacement - Sensor 2 (Heated Oxygen Sensor Replacement - Sensor 2) for the 3.7L engine.




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.





Caution: Refer to Exhaust System Inspection Caution (Exhaust System Inspection Caution).

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.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the 2 nuts securing the muffler to the catalytic converter.

* Tighten the muffler nuts by hand until each contacts the metal flange.
* Tighten the muffler nuts to 45 Nm (33 lb ft).
* Tighten the catalytic converter nuts previously installed in step 3 to 50 Nm (37 lb ft).

6. Install the HO2S if previously removed. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (Heated Oxygen Sensor Replacement - Sensor 2) for the 2.9L engine or Heated Oxygen Sensor Replacement - Sensor 2 (Heated Oxygen Sensor Replacement - Sensor 2) for the 3.7L engine.




7. Connect the HO2S at the sensor pigtail (3).
8. Install the right torsion bar. Refer to Front Torsion Bar Replacement (Front Torsion Bar Replacement).