Catalytic Converter: Service and Repair

REMOVAL
3.7L ENGINE

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

1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.





3. Disconnect oxygen sensor electrical connectors. (Fig 3)
4. Remove the nuts from the front exhaust pipe and catalytic converter assembly to muffler flange.
5. Remove bolts and flanged nuts at the manifold.
6. Lower the front exhaust pipe/catalytic converter assembly and slide out of the mount at the transmission (if equipped).
7. Remove the front exhaust pipe/catalytic converter assembly from the vehicle.

INSPECTION
Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core.

INSTALLATION
1. Position the front exhaust pipe and catalytic converter assembly into the mount at the transmission (if equipped) and onto the exhaust manifold flange connection.
2. Install the nuts at the front exhaust pipe and catalytic converter assembly to muffler flange. Do not tighten.
3. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 inch) is required.





4. Tighten the bolt at exhaust manifold to 27 Nm (19 inch lbs.) torque. (Fig. 6)
5. Tighten the front exhaust pipe and catalytic converter assembly to muffler flange nuts to 27 Nm (19 ft. lbs.) torque.
6. Position the front pipe onto the exhaust manifold flange connection. Tighten the clamp to 10 Nm (95 inch lbs.) torque.
7. Connect oxygen sensor electrical connectors.
8. Lower the vehicle.
9. Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary.
10. Check the exhaust system for contact with the body panels. Make necessary adjustments, if necessary.