Chrysler 68042142AA Exhaust And Catalytic Converter

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Lower the vehicle, remove the heat shield secured by four bolts, and then unscrew the manifold mounting bolts, guiding the manifold upward out of the engine compartment.

Remove the mounting bolts and detach the manifold from the cylinder head, ensuring to spray penetrating oil on the bolts beforehand.

Start by raising the vehicle and securing it on jackstands. If applicable, spray penetrating oil on nuts and bolts for easier loosening. For 2.4L engines (2014 and earlier), remove the oxygen sensor and rear portion of the exhaust system, then detach the converter from the exhaust manifold. For 2.7L engines, remove the front exhaust manifold/catalytic converter by disconnecting oxygen sensors and other components. For rear exhaust manifold/catalytic converter, remove the engine cover, splash shield, crossunder pipe, and oxygen sensors. For 3.5L engines, remove the front and rear exhaust manifold/catalytic converters by disconnecting oxygen sensors and other fasteners. For 3.6L engines, remove the rear catalytic converter by loosening clamps and fasteners, then guide the converter out from the bottom. Before installing the converter, use anti-seize compound on threads and tighten the fasteners securely. Installation is the reverse of removal for all models.

After completing the installation, start the engine and check for exhaust leaks between the manifold and cylinder head as well as between the manifold and exhaust pipe.

Lower the vehicle and disconnect the oxygen sensor's electrical connector in the engine compartment.

Raise the vehicle and remove the engine under cover, then detach the catalytic converter-to-exhaust manifold nuts, discarding the old gasket.

Disconnect the downstream oxygen sensor connectors and remove the under-vehicle splash shield if equipped. Unbolt the exhaust pipes at the exhaust manifolds.

Use anti-seize compound on threads and tighten the fasteners securely.

A catalytic converter is an emission control device that reduces pollutants in the exhaust gas stream. There are two types of converters: the conventional oxidation catalyst and the three-way catalyst.

Clean the manifolds with solvent and dry them with compressed air, check the mating surfaces for flatness with a precision straightedge and feeler gauges, and inspect the manifolds for cracks and distortion, replacing or resurfacing them if necessary.

For the front exhaust manifold, take out the coolant reservoir and the dipstick tube.

Clean the mating surfaces to eliminate old gasket material and inspect the manifold for distortion and cracks, checking for warpage with a precision straightedge.