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Catalytic Converter - 2.0L/2.4L: Removal

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: In the following procedure it is not necessary to separate the muffler/pipe assembly from the resonator/pipe assembly. They can both be removed as an assembly.
WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.
  1. Raise vehicle on hoist and apply penetrating oil to resonator/pipe assembly band clamp, and the fasteners that connect the catalytic converter to the exhaust manifold.
  2. Remove ground strap from muffler.
  3. Loosen band clamp for resonator/pipe assembly.
    CAUTION: Do not use any tools to remove the rubber isolators-remove by hand only. Soapy water or silicone-based lubricant spray may be used to assist removal/installation of isolators. DO NOT use a petroleum-based lubricant on the isolators, as damage to the rubber material can occur.
  4. Remove support isolators from muffler supports.
  5. Remove resonator/pipe and muffler/pipe as an assembly.
  6. Disconnect downstream oxygen sensor connector.
  7. Remove fasteners that attach catalytic converter to the exhaust manifold. Remove catalytic converter from vehicle.
  8. Remove and discard gasket.
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