Catalytic Converter: Service and Repair

Catalytic Converter Replacement (2.4L FWD)

Removal Procedure




1. Remove the 2 bolts (1) and 2 compression springs (2) from the muffler assembly.
2. Remove the gasket from the center exhaust pipe assembly.
3. Remove heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (Heated Oxygen Sensor Replacement - Sensor 2)




4. Remove the 2 bolts (1) from the front exhaust pipe assembly.
5. Remove the center exhaust pipe assembly from the 2 exhaust pipe supports.
6. Remove the gasket from the front exhaust pipe assembly.
7. Remove the center exhaust pipe assembly.

Installation Procedure





Note: If the free length is less than the minimum 38.5 mm (1.52 in), replace the compression spring.

1. Using a vernier caliper, measure the free length of the compression springs.
2. Fully insert a new gasket to the center exhaust pipe assembly.





Note: Be sure to install the gasket in the correct direction. Do not reuse the gasket.

3. Using a plastic hammer and wooden block (2) , tap in the new gasket (3) until its surface is flush with the center exhaust pipe assembly (1).
4. Connect the center exhaust pipe assembly to the 2 exhaust pipe supports.





Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the muffler assembly with the 2 bolts (1) and 2 compression springs (2). Tighten the bolts to 43 Nm (32 lb ft).




6. Install a new gasket to the front exhaust pipe assembly.
7. Install the center exhaust pipe assembly with the 2 bolts (1, 2) and tighten to 43 Nm (32 lb ft).
8. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (Heated Oxygen Sensor Replacement - Sensor 2)
9. Inspect for exhaust gas leaks.