Catalytic Converter Replacement 2.0L Diesel

Warning: Refer to Battery Disconnect Warning in the Preface section.





Warning: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials.

1. Disconnect the negative battery cable.
2. Remove the exhaust manifold heat shield.



3. Remove the exhaust front pipe. Refer to Front Pipe Replacement.
4. Remove the pre-catalyst clamp.
5. Remove the pre-catalyst bracket bolt from the engine block.
6. Remove the pre-catalyst with the seal ring.

1. Install the pre-catalyst with the seal ring. If damaged, replace the new seal ring.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the pre-catalyst clamp and the bracket bolt and tighten to 40 N·m (29.5 lb ft).



3. Install the exhaust manifold heat shield and tighten to 20 N·m (14.8 lb ft).

Catalytic Converter Replacement 2.4L

1. Remove the nuts and gasket from the exhaust front pipe-to-underbody catalytic converter (UCC).



2. Remove the nuts and gasket from the UCC-to-front muffler pipe.
3. Remove the UCC assembly.

Caution: Refer to Fastener Caution in the Preface section.




1. Install the nuts and gasket to the UCC-to-front muffler pipe and tighten to 30 N·m (22 lb ft).



2. Install the nuts and gasket to the exhaust front pipe-to-UCC and tighten to 30 N·m (22 lb ft).

Catalytic Converter Replacement 3.2L

1. Remove the 3 nuts and gasket from the exhaust front pipe-to-underbody catalytic convertor (UCC).



2. Remove the nuts and gasket from the UCC-to-front muffler pipe.
3. Remove the UCC assembly.

Caution: Refer to Fastener Caution in the Preface section.




1. Install the nuts and gasket to the UCC-to-front muffler pipe and tighten the nuts to 30 N·m (22 lb ft).



2. Install the 3 nuts and gasket to the exhaust front pipe-to-UCC and tighten nuts to 30 N·m (22 lb ft).