Jeep Wrangler/YJ 1987-1995 Repair Guide

Catalytic Converter

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REMOVAL & INSTALLATION



  1. Raise and support the rear end on jackstands.
  2.  
  3. Disconnect the downstream air injection tube at the converter.
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  5. On the 4-cylinder engine, the front pipe is bolted to the converter at a facing flange. On the 6-cylinder engines, the front pipe and converter are clamped together at a slip-fit joint. On all engines, the rear joint of the converter is a slip-fit.
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  7. To avoid damaging any components, it will probably be necessary to heat any slip-fit joint with an oxyacetylene torch, until the joint is cherry red. Then, place a block of wood against the converter and drive it off of the pipe.
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CAUTION
When using a torch, make certain that no combustibles, brake or fuel lines are in the immediate area of the torch.

  1. Position the replacement converter in the system and install the rear clamp. Hand tighten the nuts.
  2.  
  3. On 4-cylinder engines: bolt the flanges together at the front end. Tighten the bolts to 25 ft. lbs. (34 Nm). Tighten the rear clamp nuts to 45 ft. lbs. (61 Nm).
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  5. On 6-cylinder engines, install the front clamp, make sure that the converter is properly positioned and tighten the front and rear clamp nuts to 45 ft. lbs. (61 Nm).
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  7. Install the downstream air injection tube and tighten the clamps to 36-48 inch lbs. (4-5 Nm).
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  9. Lower the Jeep.
  10.  

 
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