Catalytic Converter Replacement - Right Side 6.0L Engine

1. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection.

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

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





Important: The right catalytic converter to exhaust manifold retaining (3) are single use parts. They must be discarded after removal.

2. Remove the right catalytic converter to exhaust manifold retaining nuts (3).

Discard the nuts.

3. Disconnect the right catalytic converter (2) from the exhaust manifold (1).

Caution: Refer to Vehicle Lifting Caution in the Preface section.

4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

Notice: Refer to Heated Oxygen and Oxygen Sensor Notice in the Preface section.




5. Disconnect the right pre-catalytic converter heated oxygen sensor (HO2S) electrical connector (1).




Important: The intermediate exhaust assembly to right catalytic converter retaining nuts (3) are single use parts. They must be discarded after removal.

6. Remove the intermediate exhaust assembly to right catalytic converter retaining nuts (3).

Discard the nuts.

7. Disconnect the intermediate exhaust assembly (2) from the right catalytic converter (1).



8. Remove the right catalytic converter (1) from the vehicle.
9. Remove the right pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.

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

1. Install the right pre-catalytic converter heated oxygen sensor (HO2S) to the right catalytic converter. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.




Important: Make sure that a new sealing ring if fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.

2. Install the right catalytic converter (1) to the vehicle.



3. Push up and forward on the right catalytic converter (2) to connect the exhaust manifold (1).
4. Lower the vehicle.

Important: Do not fully tighten the right catalytic converter to exhaust manifold retaining nuts (3) at this stage.

5. Install the right catalytic converter to exhaust manifold retaining nuts (3).

Do not fully tighten at this stage.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.



7. Align the intermediate exhaust assembly (2) to the right catalytic converter (1).

Notice: Refer to Fastener Notice in the Preface section.

8. Tighten the intermediate exhaust assembly to right catalytic converter retaining nuts (3).

Tighten
Tighten the nuts to 40 N·m (30 lb ft).




9. Connect the right pre-catalytic converter HO2S electrical connector (1).
10. Lower the vehicle.



11. Tighten the right catalytic converter to exhaust manifold retaining nuts (1).

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

12. Make sure the exhaust system is clear of all other components and chassis. If the exhaust system is not clear of all the other components loosen all retaining nuts and re-align. Refer to Exhaust System Alignment .
13. Connect the battery ground cable to the battery. Refer to Battery Negative Cable Disconnection and Connection.
14. If re-programming is required. Refer to Control Module References.
15. Perform diagnostic system check using diagnostic scan tool, clear all relative DTCs and inspect system for correct operation.

Catalytic Converter Replacement - Right Side 3.6L Engine

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

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

1. Ignition OFF

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the engine cover. Refer to Engine Cover Replacement.
4. Remove the right pre-catalytic convertor heated oxygen sensor (HO2S) sensor. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1.
5. Remove the right exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Right Side .




Important: The right catalytic converter to exhaust manifold retaining nuts (3) are single use parts. They must be discarded after removal.

6. Remove the right catalytic converter to exhaust manifold retaining nuts (3).

Discard the nuts.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.




Important: The exhaust crossover pipe assembly to right catalytic converter retaining nuts (3) are single use parts. They must be discarded after removal.

8. Remove the exhaust crossover pipe assembly to right catalytic converter retaining nuts (3).

Discard the nuts.

9. Pull down and back on the right catalytic converter (1) to disconnect from the exhaust manifold.
10. Disconnect the exhaust crossover pipe assembly (2) from the right catalytic converter (1).



11. Remove the right catalytic converter (1) from the vehicle.

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

Caution: Refer to Vehicle Lifting Caution in the Preface section.




1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Install the right catalytic converter (1) to the vehicle.



3. Align the exhaust crossover pipe assembly (2) to the right catalytic converter (1).

Notice: Refer to Fastener Notice in the Preface section.

4. Install NEW exhaust crossover pipe assembly to right catalytic converter retaining nuts (3).

Tighten
Tighten the nuts to 40 N·m (30 lb ft).

5. Lower the vehicle.



6. Install NEW right catalytic converter to exhaust manifold retaining nuts (1)

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

7. Make sure that the exhaust system is clear of all other components and chassis. If the exhaust system is not clear of all the other components loosen all retaining nuts and re-align. Refer to Exhaust System Alignment.
8. Install the right exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Right Side .
9. Install the right pre-catalytic convertor HO2S sensor. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1.
10. Install the engine cover. Refer to Engine Cover Replacement.
11. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .