Catalytic Converter: Service and Repair

Catalytic Converter Replacement (LLR) (3.7L)

Removal Procedure
Warning: Refer to Exhaust Service Warning (Exhaust Service Warning).
Warning: Refer to Protective Goggles and Glove Warning (Protective Goggles and Glove Warning).




1. Remove the right torsion bar. Refer to Front Torsion Bar Replacement (Service and Repair).
2. Disconnect the heated oxygen sensor (HO2S) at the sensor pigtail (3).
3. Remove the HO2S if replacement is necessary. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (Heated Oxygen Sensor Replacement - Sensor 2).





Note: Do not use oil base lubricants.

4. Apply a soapy solution to the exhaust muffler hanger rod (3) in order to ease the removal of the exhaust hanger (2), if necessary.
5. Pry the exhaust hanger (2) free from the exhaust muffler hanger rod (3), if necessary.




6. Remove the nuts securing the muffler to the catalytic converter.
7. Position the muffler rearward enough to allow the studs located in the muffler to clear the catalytic converter pipe flange.




8. Remove the nuts attaching the catalytic converter to the exhaust manifold.
9. Remove the catalytic converter.




10. Remove and discard the exhaust manifold seal at the exhaust manifold flange.

Installation Procedure




1. Install a NEW seal to the exhaust manifold flange.





Caution: Refer to Exhaust System Inspection Caution (Exhaust System Inspection Caution).

2. Install the catalytic converter to the exhaust manifold.
3. Install the nuts attaching the catalytic converter to the exhaust manifold. Do not tighten at this time.




4. Align the catalytic converter with the studs located in the muffler.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the nuts securing the muffler to the catalytic converter. Tighten the nuts by hand until each contacts the metal flange.

Tighten the nuts to 45 Nm (33 lb ft).

6. Tighten the catalytic converter nuts previously installed in step 3.

Tighten the nuts to 50 Nm (37 lb ft).

7. Install the HO2S if previously removed. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (Heated Oxygen Sensor Replacement - Sensor 2).





Note: Do not use oil base lubricants.

8. Apply a soapy solution to the following in order to ease the installation of the hanger (2):

* The inner diameter of the exhaust muffler hanger (2)
* The exhaust muffler hanger rod (3)




9. Connect the HO2S at the pigtail (3).
10. Install the right torsion bar. Refer to Front Torsion Bar Replacement (Service and Repair).