For 1990-2009 cars

## Catalytic Converter Replacement LLV/LLR - w/2WD

### Removal Procedure

Warning: Refer to Exhaust Service Warning in the Preface section.

Warning: Refer to Protective Goggles and Glove Warning in the Preface section.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Disconnect the heated oxygen sensor (HO2S) at the sensor pigtail (3).
3. Remove the HO2S if replacement is necessary. Refer to Heated Oxygen Sensor 2 Replacement for the 2.9L engine or Heated Oxygen Sensor 2 Replacement for the 3.7L engine.
4. Remove the nuts securing the muffler to the catalytic converter.
5. Position the muffler rearward, enough to allow the studs located in the front to clear the catalytic converter pipe flange.
6. Remove the 3 nuts attaching the catalytic converter to the exhaust manifold.
7. Lower the catalytic converter from the vehicle.
8. Remove the exhaust manifold seal from the exhaust manifold flange. Discard the seal.

### Installation Procedure

1. Install the NEW seal to the exhaust manifold flange.

Caution: Refer to Exhaust System Inspection Caution in the Preface section.

2. Position the catalytic converter to the exhaust manifold.
3. Install the 3 nuts attaching the catalytic converter to the exhaust manifold. Do not tighten at this time.
4. Align the catalytic converter with the studs located in the front of the muffler.

Caution: Refer to Fastener Caution in the Preface section.

5. Install the 2 nuts securing the muffler to the catalytic converter.

• | Tighten the muffler nuts by hand until each contacts the metal flange.

• | Tighten the muffler nuts to 45 N·m (33 lb ft).

• | Tighten the catalytic converter nuts previously installed in step 3 to 50 N·m (37 lb ft).

6. Install the HO2S if previously removed. Refer to Heated Oxygen Sensor 2 Replacement for the 2.9L engine or Heated Oxygen Sensor 2 Replacement for the 3.7L engine.
7. Connect the HO2S at the sensor pigtail (3).
8. Lower the vehicle.

## Catalytic Converter Replacement LLV/LLR - w/4WD

### Removal Procedure

Warning: Refer to Exhaust Service Warning in the Preface section.

Warning: Refer to Protective Goggles and Glove Warning in the Preface section.

1. Remove the right torsion bar. Refer to Torsion Bar Replacement.
2. Disconnect the heated oxygen sensor (HO2S) at the sensor pigtail (3).
3. Remove the HO2S if replacement is necessary. Refer to Heated Oxygen Sensor 2 Replacement for the 2.9L engine or Heated Oxygen Sensor 2 Replacement for the 3.7L engine.
4. Remove the nuts securing the muffler to the catalytic converter.
5. Position the muffler rearward enough to allow the studs located in the front to clear the catalytic converter pipe flange.
6. Remove the 3 nuts attaching the catalytic converter to the exhaust manifold.
7. Lower the catalytic converter from the vehicle.
8. Remove the exhaust manifold seal from the exhaust manifold flange. Discard the seal.

### Installation Procedure

1. Install the NEW seal to the exhaust manifold flange.

Caution: Refer to Exhaust System Inspection Caution in the Preface section.

2. Position the catalytic converter to the exhaust manifold.
3. Install the 3 nuts attaching the catalytic converter to the exhaust manifold. Do not tighten at this time.
4. Align the catalytic converter with the studs located in the front of the muffler.

Caution: Refer to Fastener Caution in the Preface section.

5. Install the 2 nuts securing the muffler to the catalytic converter.

• | Tighten the muffler nuts by hand until each contacts the metal flange.

• | Tighten the muffler nuts to 45 N·m (33 lb ft).

• | Tighten the catalytic converter nuts previously installed in step 3 to 50 N·m (37 lb ft).

6. Install the HO2S if previously removed. Refer to Heated Oxygen Sensor 2 Replacement for the 2.9L engine or Heated Oxygen Sensor 2 Replacement for the 3.7L engine.
7. Connect the HO2S at the sensor pigtail (3).
8. Install the right torsion bar. Refer to Torsion Bar Replacement.