Catalytic Converter: Service and Repair
CONVERTER - CATALYTICREMOVAL - 3.7L/4.7L ENGINE
CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
1. Raise and support the vehicle.
2. Saturate all exhaust bolts and nuts with Rust Penetrant. Allow 5 minutes for penetration.
3. Disconnect the oxygen senor electrical connectors.
4. Remove the catalytic converter-to-manifold bolts (5).
5. Remove the catalytic converter to the exhaust pipe clamp (1).
6. If present, grind tack weld.
7. Remove the catalytic converter. You may have to loosen up other sections of the exhaust system.
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 - 3.7L/4.7L ENGINE
CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
NOTE: The band clamps are not reusable. After removal, they must be replaced with new one.
1. Make sure the catalytic converter pipe is free of burrs.
2. Insert the catalytic converter into the exhaust pipe.
3. Make sure the alignment tang is fully seated in the alignment slot.
4. If other sections of the exhaust system where loosened in removal, refer to that information for the tightening procedures.
5. At the catalytic converter-to-extension pipe connection, install new clamp and nuts. Tighten the clamp nuts to 61 Nm (45 ft. lbs.) torque.
6. Lower the vehicle.
7. Start the engine, inspect for exhaust leaks. Repair exhaust leaks as necessary.
8. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if necessary.