C. Replace Catalytic Converter If Necessary (TJ)

1. Raise the vehicle on a suitable hoist.

2. Disconnect the front oxygen sensor from the wiring harness.





3. Remove the front oxygen sensor. Label the sensor "front" (Figure 4).

4. Disconnect the rear oxygen sensor from the wiring harness.

5. Remove the rear oxygen sensor. Label the sensor "rear".

6. Support the engine-transmission assembly at the bell housing.

7. Remove the four nuts attaching the transmission isolator to the skid plate (Figure 4).

8. Remove the skid plate.

9. Remove the transmission isolator mount.

10. Remove the transmission exhaust system bracket.

11. Remove the exhaust pipe clamp between the catalytic converter and the muffler.

12. Using a suitable torch, heat and remove the two nuts attaching the exhaust pipe flange nuts at the engine exhaust manifold.

NOTE:
Heating the exhaust pipe flange nuts will facilitate removal. Use care not to damage the exhaust manifold studs during nut removal.

13. Using a suitable torch, heat the exhaust pipe joint between the catalytic converter and muffler. Separate the catalytic converter from the muffler.

14. Insert the new exhaust pipe/catalytic converter into the muffler. Do not attach the muffler clamp at this time.

15. Position the exhaust pipe/catalytic converter assembly flange on to the exhaust manifold studs and hand start the two nuts.

16. Insert the exhaust pipe hanger hook into the transmission exhaust system rubber hanger.

17. Position the transmission exhaust system hanger and tighten the bolts to 30 ft. lbs. (41 N.m).

18. Install the transmission isolator mount and tighten the bolts to 30 ft. lbs. (41 N.m).

19. Tighten exhaust manifold to exhaust pipe nuts to 35 ft. lbs. (48 N.m).

20. Install the exhaust pipe to muffler clamp and tighten the clamp nuts to 35 ft. lbs. (48 N.m).

21. Install the rear oxygen sensor and tighten to 35 ft. lbs. (48 N.m).

22. Connect the rear oxygen sensor to the wiring harness.

23. Install the front oxygen sensor and tighten to 35 ft. lbs. (48 N.m).

24. Connect the front oxygen sensor to the wiring harness.

25. Position the skid plate such that the transmission isolator mounting studs are properly located and install the skid plate bolts. Tighten the bolts to 50 ft. lbs. (68 N.m).

26. Install and tighten the nuts fastening the transmission isolator mount to the skid plate. Tighten to 30 ft. lbs. (41 N.m).

27. Connect the battery and continue with Section D - Install the Authorized Modification Label.

NOTE:
If the catalyst replacement is due to the illumination of the MIL with DTC P0420 present, disconnect the negative battery cable and wait at least 60 seconds. This will clear all DTC(s) stored. An Authorized Modification Label for this Recall E22 should have already been affixed. Reconnect the battery cable and return the vehicle to the owner. To enhance customer satisfaction, remember to set the clock.