Catalytic Converter: Service and Repair

Catalytic Converter Replacement (L36)

Removal Procedure

Caution: Refer to Exhaust Service Caution in Service Precautions.

Caution: Refer to Protective Goggles and Gloves Caution Service Precautions.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Support the exhaust system near the resonator with a suitable jack.
3. Remove the oxygen sensor. It is not necessary to disconnect the electrical connector.





4. Remove the nuts securing the catalytic converter to the exhaust manifold pipe.





5. Remove the bolts securing the center exhaust hangers to the rear suspension support brackets.
6. Remove the catalytic converter from the manifold pipe.
7. Lower the exhaust system.
8. Remove the catalytic converter gasket. Do not reuse the gasket.





9. Cut the catalytic converter (3) from the resonator inlet pipe (1) behind the step 2 but as close to the step as the tool will permit. The replacement catalytic converter will slide over the inlet pipe.

Important: Ensure the cut (2) is made on the catalytic converter side of the pipe.

Installation Procedure





1. Lower the exhaust system only enough to install the catalytic converter to the resonator inlet pipe (1).

Important: Use care not to over extend the heated oxygen sensor pigtail.

2. Slide 2 service clamps (2) over the catalytic converter outlet pipe (3). Do not tighten at this time.Slide the catalytic converter outlet pipe (3) over the resonator inlet pipe (1), until fully seated against the heated oxygen sensor boss.

Important: Ensure the solid portion of the catalytic converter heat shield is upward.





3. Place a NEW catalytic converter gasket over the catalytic converter studs.

Notice: Refer to Exhaust System Inspection Notice in Service Precautions.

4. Raise the exhaust system into position, aligning the catalytic converter with the exhaust manifold pipe.

Notice: Refer to Flex Decoupler Notice in Service Precautions.

5. Install the nuts securing the catalytic converter to the exhaust manifold pipe. Do not tighten at this time.





6. Install the bolts securing the center exhaust hangers to the rear suspension support brackets.
Tighten the center exhaust hanger bolts to 30 Nm (22 lb ft).

Notice: Refer to Fastener Notice in Service Pracautions.

7. Install the catalytic converter nuts.
Tighten the catalytic converter nuts in a crisscross pattern to 25 Nm (18 lb ft).

8. Remove the jack from under the vehicle.
9. Position the service clamps midway on the catalytic converter outlet pipe, as close together as possible.

Important: Ensure the catalytic converter outlet pipe is fully seated against the heated oxygen sensor boss.

10. Rotate the clamps so the fastening ends are pointing in opposite directions.
Tighten the service clamps to 30 Nm (22 lb ft).
11. Install the oxygen sensor.
Tighten to 41 Nm (30 lb ft).
12. Lower the vehicle.
13. Check the exhaust system for leaks.