Chrysler Concorde/Intrepid/LHS/New Yorker/Vision 1993-1997

Catalytic Converter

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REMOVAL & INSTALLATION



Non Flex Fuel
  1. Remove the exhaust system from the vehicle.
  2.  
  3. Cut the coverter-to-intermidiate pipe just in front of the muffler.
  4.  

To install:
  1. Install the new converter onto the intermediate pie, then install the new clamps loosely.
  2.  
  3. Install the front pipes.
  4.  
  5. Install the exhaust system to the vehicle.
  6.  
  7. Start the engine and check for leaks.
  8.  

Flex Fuel
LEFT SIDE

See Figure 1



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Fig. Fig. 1: The catalytic converters are attached directly to the exhaust manifolds on the flex fuel engines

  1. Disconnect the battery cables, negative first.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Disconnect and remove the oxygen sensor.
  6.  
  7. Remove the bolts holding the front pipe hangers to the transaxle bracket.
  8.  
  9. Support the exhaust system with a jack stand.
  10.  
  11. Remove the bolts holding the left and right front pipes to the back of the converters, then lower the system.
  12.  
  13. Remove the bolts holding the converter to the exhaust manifold flange. Discard the flange gasket.
  14.  
  15. Remove the converter through the opening between the floor pan and the crossmember.
  16.  

To install:
  1. Install the converter to the exhaust manifold using a new gasket. Tighten the flange bolts to 19 ft. lbs. (26 Nm).
  2.  
  3. Install the exhaust system to the vehicle.
  4.  
  5. Install the front pipe hanger bolts and tighten to 45 ft. lbs. (61 Nm).
  6.  
  7. Install the oxygen sensor and tighten to 20 ft. lbs. (27 Nm).
  8.  
  9. Lower the vehicle.
  10.  
  11. Connect the battery cables, positive first.
  12.  

RIGHT SIDE
  1. Remove the air cleaner housing and the air inlet hose.
  2.  
  3. Disconnect and remove the downstream oxygen sensor.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the bolts holding the right pipe to the converter.
  8.  
  9. Lower the vehicle.
  10.  
  11. Remove the bolts holding the converter to the exhaust manifold flange. Do not reuse the flange gasket.
  12.  
  13. Remove the converter.
  14.  

To install:
  1. Install the converter to the exhaust manifold using a new gasket. Tighten the flange bolts to 19 ft. lbs. (26 Nm).
  2.  
  3. Raise and support he vehicle.
  4.  
  5. Install the front pipe to converter bolts.
  6.  
  7. Lower the vehicle.
  8.  
  9. Install the oxygen sensor and tighten to 20 ft. lbs. (27 Nm).
  10.  
  11. Install the air cleaner housing and inlet hose at the throttle body.
  12.  

 
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