Catalytic Converter Replacement - Right

Catalytic Converter Replacement - Right (3.5L)
Tools Required
^ J39194-B Heated Oxygen Sensor Wrench

Removal Procedure





1. Remove the muffler assembly.
2. Remove the connector position assurance (CPA) retainer (1).

3. Important: The heated oxygen sensor (HO2S) 2 uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

Disconnect the HO2S electrical connector (2).





4. Remove the HO2S (2) using the J39194-B.





5. Remove the left catalytic converter to right catalytic converter nuts (3). (Powertrain shown removed for clarity).





6. Remove the catalytic converter bolt (4) and nuts (1) at the exhaust manifold.
7. Remove the right catalytic converter (3).
8. Remove and discard the gasket (2).
9. Inspect the catalytic converter-to-exhaust manifold flange.
^ Service Limit: 0.7 mm (0.028 inch) maximum
^ Standard: 0.7 mm (0.028 inch) maximum

Installation Procedure





1. Install a NEW gasket (2) to the catalytic converter studs.
2. Install the right catalytic converter (3).

3. Notice: Refer to Fastener Notice.

Install the catalytic converter bolt (4) and nuts (1) at the exhaust manifold.
Tighten the bolt and nuts to 31 Nm (23 ft. lbs.).





4. Install the left catalytic converter to right catalytic converter nuts (3). (Powertrain shown removed for clarity).
Tighten the nuts to 31 Nm (23 ft. lbs.).





5. Install the HO2S (2) using the J39194-B.
Tighten the sensor to 42 Nm (31 ft. lbs.).
6. Lower the vehicle to the ground, start the engine, and check for exhaust leaks.





7. Connect the HO2S electrical connector (2).
8. Install the CPA retainer (1).
9. Install the muffler assembly.
10. Start the engine, and check for exhaust leaks.