Catalytic Converter

Fig 1: Converter to Exhaust Manifold Connection - 2.4L

Courtesy of CHRYSLER LLC

NOTE: When assembling exhaust system do not tighten clamps until all components are aligned and clearances are checked.

Assemble catalytic converter (2) to exhaust manifold connection. Use a new flange gasket (1).
Tighten the catalytic converter (2) to exhaust manifold fasteners to 28 N.m (250 in. lbs.).
Install intermediate pipe and muffler. See Exhaust System/PIPE, Intermediate - Installation .
Working from the front of system; align each component to maintain position and proper clearance with underbody parts. For clearance specifications. See Exhaust System - Specifications .
Tighten band clamps to 47 N.m (35 ft. lbs.).

Fig 2: Downstream 1/2 Oxygen Sensor - Typical
Courtesy of CHRYSLER LLC

1 - DOWN STREAM O2 SENSOR

2 - UP STREAM O2 SENSOR

CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced.
If removed, install downstream oxygen sensor (1).
Connect downstream oxygen sensor (1) electrical connector.
Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.