Catalytic Converter Replacement 3.8L

Important: The 3-way catalytic converter is serviced by replacing the entire assembly. Always replace the gaskets when servicing the 3-way catalytic converter assembly. Never install the original gaskets.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Disconnect the heated oxygen sensor (HO2S) electrical connector.
3. Remove the exhaust manifold pipe stud nuts.



4. Remove the catalytic converter nuts.



5. Remove the catalytic converter hangers.
6. Remove the 3-way catalytic converter.
7. Remove the gasket from the exhaust pipe.
8. Remove the gasket from the exhaust manifold.
9. Clean and inspect the exhaust manifold and the exhaust pipe gasket mating surfaces.



10. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor 2 Replacement in Engine Controls - 3.8L.

1. Install the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor 2 Replacement in Engine Controls - 3.8L.



2. Install a new gasket to the exhaust pipe studs.
3. Install a new gasket to the exhaust manifold.

Notice: Refer to Catalytic Converter Movement Notice in the Preface section.

4. Install and support the 3-way catalytic converter.
5. Install the catalytic converter nuts.

Notice: Refer to Fastener Notice in the Preface section.




6. Install the exhaust manifold pipe stud nuts.

Tighten

•	Tighten the exhaust manifold pipe stud nuts to 35 N·m (26 lb ft).

•	Tighten the catalytic converter nuts to 60 N·m (44 lb ft).




7. Install the catalytic converter hangers.
8. Connect the heated oxygen sensor (HO2S) electrical connector.
9. Lower the vehicle.
10. Inspect the exhaust system for leaks.

Catalytic Converter Replacement 3.4L

Important: The 3-way catalytic converter is serviced by replacing the entire assembly. Always replace the gaskets when servicing the 3-way catalytic converter assembly. Never install the original gaskets.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Disconnect the heated oxygen sensor (HO2S) electrical connector.
3. Remove the exhaust manifold pipe stud nuts.
4. Remove the exhaust manifold pipe gasket.



5. Remove the catalytic converter nuts.



6. Remove the catalytic converter hangers.
7. Remove the 3-way catalytic converter.
8. Remove the gasket from the exhaust pipe.
9. Clean and inspect the exhaust manifold and the exhaust pipe gasket mating surfaces.



10. Remove the heated oxygen sensor (HO2S) from the catalytic converter. Refer to Heated Oxygen Sensor 2 Replacement in Engine Controls - 3.4L.

1. Install the heated oxygen sensor (HO2S) to the catalytic converter. Refer to Heated Oxygen Sensor 2 Replacement in Engine Controls - 3.4L.




Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

2. Install a new gasket to the exhaust pipe studs.
3. Install a new exhaust manifold pipe gasket.

Notice: Refer to Catalytic Converter Movement Notice in the Preface section.

4. Install and support the 3-way catalytic converter.
5. Install the catalytic converter nuts.

Notice: Refer to Fastener Notice in the Preface section.




6. Install the exhaust manifold pipe stud nuts.

Tighten

•	Tighten the exhaust manifold pipe stud nuts to 35 N·m (26 lb ft).

•	Tighten the catalytic converter nuts to 60 N·m (44 lb ft).




7. Install the catalytic converter hangers.
8. Connect the heated oxygen sensor (HO2S) electrical connector.
9. Lower the vehicle.
10. Inspect the exhaust system for leaks.