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Catalytic Converter

Engine, Cooling and Exhaust › Exhaust System
Unified entry — merged from multiple cross-listed pages in the original manual.

Parts

PartCatalytic Converter
ManufacturerCHY
OEM part #52125351AD
Price$1085.00
NotesIncludes Front Pipe.

Labor

Replace2.0 hr
Warranty 1.5 hrSkill B
Procedures
Catalytic Converter - Installation10 steps
Fig. 1
Fig. 1
  1. Position the front exhaust pipe and catalytic converter assembly (3) into the mount at the transmission (if equipped) and onto the exhaust manifold flange connection.
  2. Install the nuts at the front exhaust pipe and catalytic converter assembly to muffler flange. Do not tighten.
  3. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 in.) is required.
  4. Tighten the bolt (1) at exhaust manifold to 27 Nm (19 in. lbs.) torque.
  5. Tighten the front exhaust pipe and catalytic converter assembly to muffler flange nuts to 27 Nm (19 ft. lbs.) torque.
  6. Position the front pipe onto the exhaust manifold flange connection. Tighten the clamp to 10 Nm (95 in. lbs.) torque.
  7. Connect oxygen sensor electrical connectors.
  8. Lower the vehicle.
  9. Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary.
  10. Check the exhaust system for contact with the body panels. Make adjustments, if necessary.
Catalytic Converter - Removal7 steps
⚠ WARNING
If torches are used when servicing the exhaust system, do not allow any flame near the fuel lines or the fuel tank. Failure to follow these instructions may result in possible serious or fatal injury.
Fig. 1
Fig. 1
  1. Raise and support the vehicle.
  2. Saturate the bolts (1) and nuts with heat valve lubricant. Allow 5 minutes for penetration.
  3. Disconnect oxygen sensor electrical connectors.
  4. Remove the nuts from the front exhaust pipe and catalytic converter assembly to muffler flange.
  5. Remove bolts (1) and flanged nuts at the manifold.
  6. Lower the front exhaust pipe/catalytic converter assembly (3) and slide out of the mount at the transmission (if equipped).
  7. Remove the front exhaust pipe/catalytic converter assembly from the vehicle.
Catalytic Converter: Description and Operationreference
⚠ 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.
△ CAUTION
DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter.
DESCRIPTION The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. Unleaded gasoline must be used to avoid contaminating the catalyst core. 50 State emission vehicles incorporate two catalytic converters located after the exhaust manifolds and before the muffler.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
CONVERTER-CATALYTIC📷 2

Description

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.
CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the
converter.
The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage.
Unleaded gasoline must be used to avoid contaminating the catalyst core.
50 State emission vehicles incorporate two catalytic converters located after the exhaust manifolds and before the muffler.
figure
figure
REMOVAL-2.8L DIESEL📷 1
1 - NUT 2 - MOUNTING BOLT 3 - CATALYTIC CONVERTER
WARNING: If torches are used when working on the exhaust system, do not allow the flame near the fuel lines.
  1.   Raise and support the vehicle.
  2.   Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
  3.   Remove diesel particulate filter (DPF), if equipped.
  4.   Remove two bracket bolts (2).
5. Remove the nuts (1) from the front catalytic converter to turbocharger flange. 6. Lower the catalyst assembly (2) and slide out of the mount at the transmission (if equipped). 7. Remove the front exhaust pipe/catalytic converter assembly from the vehicle.
figure
REMOVAL-3.7L ENGINE📷 1
WARNING: If torches are used when working on the exhaust system, do not allow the flame near the fuel lines.
1. Raise and support the vehicle.
2. Saturate the bolts (1) and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect oxygen sensor electrical connectors. 4. Remove the nuts from the front exhaust pipe and catalytic converter assembly to muffler flange. 5. Remove bolts (1) and flanged nuts at the manifold. 6. Lower the front exhaust pipe/catalytic converter assembly (3) and slide out of the mount at the transmission (if equipped). 7. Remove the front exhaust pipe/catalytic converter assembly from the vehicle.

Inspection

Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core.
figure
INSTALLATION-2.8L DIESEL📷 1
1 - NUT 2 - MOUNTING BOLT 3 - CATALYTIC CONVERTER
1. Position the front catalytic converter assembly (3) onto the turbocharger. 2. Install two catalytic converter mounting bolts. Tighten bolts to 27 N.m (19 ft. lbs.) torque.
3. Install DPF, if equipped. See REMOVAL. 4. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 in.) is required. 5. Lower the vehicle. 6. Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary. 7. Check the exhaust system for contact with the body panels. Make adjustments, if necessary.
figure
INSTALLATION-3.7L ENGINE📷 1
1. Position the front exhaust pipe and catalytic converter assembly (3) into the mount at the transmission (if
equipped) and onto the exhaust manifold flange connection. 2. Install the nuts at the front exhaust pipe and catalytic converter assembly to muffler flange. Do not tighten. 3. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 in.) is required.
 4.   Tighten the bolt (1) at exhaust manifold to 27 N.m (19 in. lbs.) torque.
 5.   Tighten the front exhaust pipe and catalytic converter assembly to muffler flange nuts to 27 N.m (19 ft.
lbs.) torque. 6. Position the front pipe onto the exhaust manifold flange connection. Tighten the clamp to 10 N.m (95 in. lbs.) torque.
 7.   Connect oxygen sensor electrical connectors.
 8.   Lower the vehicle.
 9.   Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary.
10.   Check the exhaust system for contact with the body panels. Make adjustments, if necessary.
figure