Catalytic Converter — 3.7L

Removal

NOTE: Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .

2. NOTICE: When repairing the exhaust system or removing exhaust components, disconnect all Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) at the wiring connectors to prevent damage to the sensors and wiring harnesses.

   Disconnect the RH and LH Heated Oxygen Sensor (HO2S) electrical connectors.

3. Disconnect the RH and LH Catalyst Monitor Sensor (CMS) electrical connectors.

4. Using a jackstand, support the catalytic converter.

5. Loosen the Torca® couplers.
   • Slide the Torca® couplers on to the intermediate pipe and disconnect the intermediate pipe from the catalytic converter assembly.

6. Remove and discard the 2 RH catalytic converter-to-exhaust manifold nuts.

7. Remove and discard the 2 LH catalytic converter-to-exhaust manifold nuts.

8. Remove the jackstand and the catalytic converter.

Installation

1. NOTICE: Prior to installation, inspect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) wiring harness for damage.

   NOTE: Using a Scotch Brite® pad, clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare, at the catalytic converter outlet flare and the muffler inlet pipe. Keep foreign materials out of the catalytic converters.

   NOTE: Using a jackstand, support the catalytic converter near the rear outlet while positioning the converter into place. Align the manifold studs into the pipe flange. Make sure not to damage the studs or mating surfaces.

   NOTE: Hand-tighten all the catalytic converter nuts.

   Install the catalytic converter and hand tighten the new LH and RH catalytic converter-to-exhaust manifold nuts.
   • Do not tighten the LH and RH catalytic converter-to-exhaust manifold nuts at this time.

2. NOTE: Similar catalytic converter shown.

   NOTE: Make sure that the catalytic converter is inserted into the couplers correctly.

   Slide the Torca® couplers over catalyst pipes and engage the coupler clip completely over the converter button.
   • Do not tighten the Torca® couplers at this time.

3. NOTE: Tighten the catalytic converter-to-exhaust manifold nuts alternately in 10 Nm (89 lb-in) increments to maintain torque and draw flange evenly to assure alignment of exhaust system. Tighten the new nuts to 40 Nm (30 lb-ft).

   NOTE: Make sure to correctly align the catalytic converter to the exhaust manifold and intermediate pipes before tightening the fasteners.

   Tighten the 2 LH catalytic converter-to-exhaust manifold nuts.
   • Tighten to 40 Nm (30 lb-ft).
     • Alternately tighten, in 10 Nm (89 lb-in) increments.

4. NOTE: Tighten the catalytic converter-to-exhaust manifold nuts alternately in 10 Nm (89 lb-in) increments to maintain torque and draw flange evenly to assure alignment of exhaust system. Tighten the new nuts to 40 Nm (30 lb-ft).

   Tighten the 2 RH catalytic converter-to-exhaust manifold nuts.
   • Tighten to 40 Nm (30 lb-ft).
     • Alternately tighten, in 10 Nm (89 lb-in) increments.

5. Tighten the Torca® couplers.
   • Tighten to 48 Nm (35 lb-ft).

6. Connect the RH and LH CMS electrical connectors.

7. Connect the RH and LH HO2S electrical connectors.