Catalytic Converter: Service and Repair
CONVERTER - CATALYTIC8.3L ENGINE
1. Raise and support vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Disconnect oxygen sensor electrical connectors.
4. Remove LH exhaust pipe to manifold bolts (2), retainers and nuts (1).
5. Remove LH catalytic converter to muffler clamp nuts (4).
6. Rotate LH catalytic converters (6) from the muffler (5).
7. Remove RH exhaust pipe to manifold bolts (2), retainers and nuts (1).
8. Remove RH catalytic converter to muffler clamp nuts (4).
9. Rotate RH catalytic converter (3) from the muffler (5).
10. Remove clamps and nuts (4).
INSPECTION
Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core.
INSTALLATION
1. Make sure catalytic converters (3, 6) and mufflers (5) are free of burrs.
2. Insert RH catalytic converter (3) into muffler (5).
3. Make sure the alignment tang on the catalytic converter (3) seats in the alignment slot on the muffler (5).
4. Position the catalytic converter (3) to the exhaust manifold. Install and hand tighten bolts (2), retainers and nuts (1).
5. Insert LH catalytic converter (6) into muffler (5).
6. Make sure the alignment tang on the catalytic converter (6) seats in the alignment slot on the muffler (5).
7. Position the catalytic converter (6) to the exhaust manifold. Install and hand tighten bolts (2), retainers and nuts (1)
8. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Clearance between catalytic converter and frame is 15 mm (0.59 inch). Make the necessary adjustments, if needed.
9. Tighten catalytic converter to exhaust manifold bolts (2) to 20.3 Nm (15 ft. lbs.) torque.
10. Tighten the clamp nuts to 54.2 Nm (40 ft. lbs.) torque.
11. Lower the vehicle.
12. Start the engine and inspect for exhaust leaks. and exhaust system. Repair exhaust leaks as necessary.