Catalytic Converter Replacement - Right (3.9L W/RPO M15)

Catalytic Converter Replacement - Right (3.9L w/RPO M15)
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 lower right HO2S electrical connector (2).





4. Remove the lower right 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 right catalytic converter bolt (4) and nuts (1) at the exhaust manifold.
7. Remove the right catalytic converter (3).
8. Remove and discard the gasket.
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 to the catalytic converter studs.
2. Install the right catalytic converter (3).

Notice: Refer to Fastener Notice.

3. Install the catalytic converter bolt (4) and nuts (1) at the exhaust manifold.
Tighten the 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. Connect the lower right HO2S electrical connector (2).
7. Install the CPA retainer (1).
8. Ensure that the HO2S connector clip (3) is attached to the stud on the engine.
9. Install the muffler assembly.
10. Start the engine, and check for exhaust leaks.