Rear

CATALYTIC CONVERTER - REAR - 2.7L
REMOVAL
1. Disconnect negative battery cable.
2. Raise vehicle on hoist.
3. Remove entire exhaust system from vehicle
4. Remove exhaust cross-under pipe.
5. Disconnect upstream oxygen sensor.





6. Remove nuts attaching converter to exhaust manifold (Fig. 6).
7. Remove exhaust manifold heat shield.
8. Remove catalytic converter.
9. Remove and discard gasket.

INSPECTION

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.

Check catalytic converter for a flow restriction. Refer to Exhaust System Restriction Check for procedure.
Visually inspect the catalytic converter element by using a borescope or equivalent. Remove both oxygen sensors and insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect element for cracked or melted substrate.

NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to appropriate Diagnostic Information for test procedures.

INSTALLATION
1. Clean manifold to converter sealing surfaces.
2. Position new gasket on converter inlet flange (Fig. 6).
3. Install converter to exhaust manifold.
4. Install exhaust manifold heat shield into position.
5. Install nuts attaching converter to manifold. Torque nuts to 28 Nm (250 inch lbs.).
6. Connect upstream oxygen sensor.
7. Install cross-under pipe.
8. Install exhaust system on vehicle.
9. Lower vehicle.
10. Connect negative battery cable.
11. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
12. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.