Catalytic Converter — 5.0L

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.

NOTE: Discard the ball clamps and fasteners after removal.

All catalytic converters

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

RH catalytic converter

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

All catalytic converters

3. Using a jackstand, support the catalytic converter.

4. NOTICE: When repairing the exhaust system or removing exhaust components, disconnect the Catalyst Monitor Sensor (CMS) at the wiring connector to prevent damage to the sensor and wiring harness.

   Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.

5. Loosen the catalytic converter-to-exhaust H-pipe ball clamp.

RH catalytic converter

6. Remove and discard the RH catalytic converter-to-exhaust manifold nut.
   • Remove the RH catalytic converter and discard the gasket.

LH catalytic converter

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

All catalytic converters

8. Remove and discard the ball clamp from the exhaust H-pipe.

Installation

All catalytic converters

1. Install a new ball clamp on the exhaust H-pipe.

LH catalytic converter

2. NOTICE: Prior to installation, inspect 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 exhaust H-pipe. Keep foreign materials out of the catalytic converters.

   NOTE: Hand-tighten all the catalytic converter nuts.

   Install the LH catalytic converter, gasket and 2 new nuts.
   • Do not tighten the LH catalytic converter-to-exhaust manifold nuts at this time.

RH catalytic converter

3. NOTICE: Prior to installation, inspect 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 exhaust H-pipe. Keep foreign materials out of the catalytic converters.

   NOTE: Hand-tighten all the catalytic converter nuts.

   Install the RH catalytic converter, gasket and 2 new nuts.
   • Do not tighten the RH catalytic converter-to-exhaust manifold nuts at this time.

All catalytic converters

4. Using a jackstand, support the exhaust H-pipe.

LH catalytic converter

5. NOTE: Tighten the LH 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 exhaust H-pipe 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.

RH catalytic converter

6. NOTE: Tighten the RH 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 exhaust H-pipe before tightening the fasteners.

   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.

All catalytic converters

7. Tighten the catalytic converter-to-exhaust H-pipe ball clamp.
   • Tighten to 30 Nm (22 lb-ft).

8. Connect the Catalyst Monitor Sensor (CMS) electrical connector.