Service Procedure

FIGURE 1:

A. Install a New Catalytic Converter

1. Saturate the nuts at the front of the converter and exhaust pipe clamp at the rear of the converter with Mopar Rust Penetrant PN 4318039 or equivalent (Figure 1). Allow 5 minutes for penetration.
2. Remove the nuts, studs, springs and exhaust pipe clamp and discard.

3. Heat the rear exhaust pipe-to-converter joint with an oxyacetylene torch until metal becomes cherry red.

4. While the joint is hot, twist the converter back and forth until it becomes disengaged from the rear exhaust pipe.

5. Remove the exhaust seal from the exhaust manifold.

6. Connect the new converter to the rear exhaust pipe and install a new clamp from the parts package. Do not tighten the nuts.

7. Attach the front of the converter to the exhaust manifold using new provided exhaust seal, springs, studs, and nuts. Do not tighten the nuts.

8. Align the pipe and tighten the new clamp at the rear exhaust pipe.

9. Tighten the manifold-to-catalytic converter attaching nuts to 27 N-m (20 ft.lbs).

Caution: The spring coils must never be compressed to touch. If they are touching, loosen the nuts until the coils separate slightly.

B. Install the recall completion label:

1. With a ball point pen, print your dealer code (5 digits) on the supplied recall completion label.

2. Peel the label from its backing and apply it near the vehicle emission control information label, located on the underside of the hood.