Catalytic Converter: Service and Repair

REMOVAL

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.

WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.

CAUTION: When servicing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust system to hang by the oxygen sensor harness will damage the wiring and/or sensor.

1. Raise and support the vehicle.
2. Saturate the studs and nuts with a Mopar rust penetrant. Allow 5 minutes for penetration.
3. Remove the oxygen sensors from the exhaust pipe and the catalytic converter.
4. Disconnect the exhaust pipe from the engine exhaust manifold.
5. Remove catalytic converter to muffler flange retaining nuts.
6. Slide exhaust pipe forward until exhaust pipe hanger disengages from transmission support. Remove exhaust pipe and catalytic converter from vehicle.

INSTALLATION
1. Position exhaust pipe and catalytic converter into vehicle.
2. Insert exhaust pipe hanger into transmission support.
3. Install exhaust pipe onto exhaust manifold DO NOT tighten bolts at this time.





4. Position muffler flange onto catalytic converter flange and install retaining bolts and nuts. DO NOT tighten nuts at this time.
5. Make sure the exhaust system is aligned and has the proper clearance. The minimum clearance is 25 mm (1 inch).
6. Tighten muffler to catalytic converter flange retaining nuts to 28.5 Nm (21 ft. lbs.).
7. Tighten exhaust pipe to exhaust manifold mounting bolts to 31 Nm (23 ft. lbs.).
8. Install the oxygen sensors in the exhaust pipe and catalytic converter.
9. Lower vehicle.
10. Start engine check for leaks.