Catalytic Converter: Removal

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER 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.

CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country (particularly vehicles built for States with strict emission requirements) and between model years.

NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter failures are caused by air, fuel or ignition problems. Refer to the appropriate service diagnostic information for repair procedures.

NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or equivalent) must be used.

Remove muffler and intermediate pipe. See MUFFLER and INTERMEDIATE PIPE .
Disconnect downstream oxygen sensor electrical connector. See Fig 1 .

Fig 1: Disconnecting Downstream 1/2 Oxygen Sensor
Courtesy of DAIMLERCHRYSLER CORP.
Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle Fig 2 .
Remove and discard flange gasket.

Fig 2: Disconnecting Catalytic Converter to Exhaust Manifold Connection

Courtesy of DAIMLERCHRYSLER CORP.