Catalytic Converter: Service and Repair

CATALYTIC CONVERTER

REMOVAL - 2.4L

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.

CAUTION: When servicing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust system to hang by the oxygen sensor harness will damage the wiring and/or sensor.

1. Disconnect the oxygen sensors.





2. Remove the two bolts and flanged nuts at the manifold.
3. Remove the two bolts and flanged nuts at the flange.
4. Remove the mini catalyst assembly from the vehicle.
5. Slide exhaust pipe toward until exhaust pipe hanger disengages from transmission support. Remove exhaust pipe and catalytic converter from vehicle.

INSTALLATION - 2.4L
1. Position the mini catalytic converter assembly onto the exhaust pipe flange and the exhaust manifold. Tighten the nuts to 31 Nm (23 ft. lbs.) torque. Tighten the flange nuts to 28 Nm (21 ft. lbs.).
2. Connect oxygen sensor wiring.
3. Lower the vehicle.
4. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed.