GrandCaravan 2008

Exhaust System

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Catalytic Converter



Removal & Installation
3.3L & 3.8L Engines

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
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.


NOTE
When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent).

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Loosen the clamp and disconnect the muffler and resonator assembly from the catalytic converter pipe.
  6.  
  7. Disconnect the downstream oxygen sensor electrical connector.

    Click image to see an enlarged view

    Fig. Disconnect the downstream oxygen sensor electrical connector-3.3L and 3.8L engines

  8.  
  9. Remove the catalytic converter-to-exhaust manifold attaching bolts (3).
  10.  
  11. Remove the catalytic converter (4) and the gasket.

    Click image to see an enlarged view

    Fig. Remove the catalytic converter and the gasket

  12.  

To install:

  1. Position a new gasket (2) onto the manifold flange and install the catalytic converter (4). Tighten the bolts (3) to 27 ft. lbs. (37 Nm).
    WARNING
    Be careful not to twist or kink the oxygen sensor wires.

  2.  
  3. Install and connect the downstream oxygen sensor electrical connector, if removed.
  4.  
  5. Install the muffler/resonator assembly.
  6.  
  7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks, as necessary.
  8.  
  9. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
  10.  

4.0L Engine

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
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.


NOTE
When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent).

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Disconnect the exhaust system at the catalytic converter outlet.
  8.  
  9. Remove the accessory drive belt shield.
  10.  
  11. Disconnect the downstream oxygen sensor connector.
  12.  
  13. Disconnect the catalytic converter pipe (4) from the exhaust manifold.

    Click image to see an enlarged view

    Fig. Remove the catalytic converter and the gasket

  14.  

To install:

  1. Attach the catalytic converter pipe (4) to the exhaust manifold using a new gasket and tighten the bolts to 27 ft. lbs. (37 Nm).
  2.  
  3. Connect the downstream oxygen sensor connector.
  4.  
  5. Connect the exhaust system at the catalytic converter outlet.
  6.  
  7. Install the belt splash shield and lower the vehicle.
  8.  
  9. Connect the battery negative cable.
  10.  
  11. Start the engine and inspect for exhaust leaks. Repair exhaust leaks, as necessary.
  12.  
  13. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
  14.  

 
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