Catalytic Converter: Service and Repair
REMOVAL2.4L ENGINE
WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Disconnect oxygen sensor electrical connector.
4. Remove the bolts from the front exhaust pipe/catalytic converter assembly to muffler flange. (Fig. 2)
5. Remove bolts and flanged nuts at the manifold.
6. Lower the catalyst assembly and slide out of the mount at the transmission (if equipped).
7. Remove the front exhaust pipe/catalytic converter assembly from the vehicle.
INSPECTION
Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core.
INSTALLATION
1. Position the front exhaust pipe and catalytic converter assembly into the the mount at the transmission (if equipped) and onto the exhaust manifold flange connection.
2. Install the bolts at the muffler and front pipe connection. Do not tighten.
3. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 inch) is required.
4. Tighten the bolt at exhaust manifold to 27 Nm (19 inch lbs.) torque. (Fig. 5)
5. Tighten the front exhaust pipe and catalytic converter assembly to muffler flange nuts to 27 Nm (19 ft. lbs.) torque.
6. Connect oxygen sensor electrical connector.
7. Lower the vehicle.
8. Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary.
9. Check the exhaust system for contact with the body panels. Make necessary adjustments, if necessary.