Catalytic Converter: Notes

REMOVAL 

1. Remove the exhaust pipe. Refer to PIPE, EXHAUST, REMOVAL AND INSTALLATION .
2. Remove the two wire harness retainers from bellhousing studs.
3. Remove the sway bar heat shield fastener and the sway bar heat shield.
4. Remove the lower EGR tube bolts.
5. Remove the top portion of the cowl cover silencer. Refer to SILENCER, COWL EXTENSION, REMOVAL AND INSTALLATION .
6. Remove the upstream oxygen sensor. Refer to OXYGEN SENSORS .
7. Remove the coolant line nut at the turbocharger and reposition the coolant line.
8. Remove the upper turbocharger heat shield. Refer to TURBOCHARGER HEAT SHIELDS .
9. Remove the nuts and the EGR tube.
10. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
11. Remove the downstream oxygen sensor. Refer to OXYGEN SENSORS .
12. If equipped, remove the Exhaust Gas Temperature (EGT) sensor. Refer to SENSOR, EXHAUST TEMPERATURE, REMOVAL AND INSTALLATION .
13. If equipped, disconnect the differential pressure sensor hoses.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Differential Pressure Sensor Hoses

14. Loosen the catalytic converter to turbocharger exhaust clamp bolt.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Catalytic Converter to Turbocharger Exhaust Clamp Bolt

    2 - Exhaust Clamp

    3 - Catalytic Converter

15. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
16. Remove the nuts and the catalytic converter heat shield.
17. Remove the catalytic converter support bracket bolts.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Catalytic Converter Support Bracket Bolts

18. Remove the catalytic converter support bracket nuts and the catalytic converter support bracket.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Catalytic Converter Support Bracket

    2 - Catalytic Converter Support Bracket Nuts

19. Remove the catalytic converter from the bottom of the vehicle.
20. Clean the gasket sealing surfaces.

INSPECTION AND CLEANING 

INSPECTION 

• Look at the stainless steel body of the Catalytic Converter assembly, inspect for bulging or other distortion that could be a result of overheating.
• Indication of exhaust gas leakage such as soot trails.
• Joint misalignment.
• Denting of greater than 6.3 mm (0.25 in.).
• Outer shell torn, cracked or otherwise damaged.
• Loose or damaged core.

INSTALLATION 

Follow the removal procedure in reverse for general reassembly of the components on the vehicle. The steps listed below are calling out specific procedures that should be followed during installation.

• Install the exhaust gas temperature sensor and securely tighten the exhaust gas temperature sensor.
• Make sure the catalytic converter is correctly positioned and properly aligned. The minimum clearance between components is 25.4 mm (1 in.) is required.
• Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary. Refer to LEAK TESTING  .