Catalytic Converter: Service and Repair

CONVERTER-CATALYTIC

REMOVAL






CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.

1. Raise and support the vehicle.
2. Saturate all exhaust bolts and nuts with Mopar Rust Penetrant. Allow 5 minutes for penetration.
3. Disconnect the oxygen senor electrical connectors.
4. Remove the catalytic converter-to-manifold bolts (5).
5. Remove the clamp (1) holding the catalytic converter (3) to the exhaust pipe(s) (2).
6. If present, grind tack weld.
7. Remove the clamp holding the catalytic converter flange to the muffler or extension pipe.
8. Remove the catalytic converter. You may have to loosen up other sections of the exhaust system.

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



CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.

NOTE: The band clamps are not reusable. After removal, they must be replaced with new one.

1. Make sure the catalytic converter assembly (3) is free of burrs.
2. Insert the catalytic converter assembly (3) into the exhaust pipe (2).
3. Make sure the alignment tang is fully seated in the alignment slot.
4. Position catalytic converter assembly (3) to exhaust manifold and install flange nuts (5) and bolts (4). Hand tighten at this time.
5. If other sections of the exhaust system where loosened in removal, refer to that information for the tightening procedures.
6. At the catalytic converter-to-extension pipe connection, install new clamp (1) and nuts. Hand tighten at this time.
7. Make sure the catalytic converter assembly (3) is correctly positioned and properly aligned. The minimum clearance between components is 25 mm (1 inch). Ensure that muffler isolators are not stretched. Measurement between insulator rods is approximately 42 mm (1.65 inch). Make the necessary adjustments, if necessary
8. Tighten exhaust manifold flange bolts to 33 Nm (25 ft. lbs.).
9. Tighten the clamp nuts to 61 Nm (45 ft. lbs.).
10. Lower the vehicle.
11. Start the engine, inspect for exhaust leaks. Repair exhaust leaks as necessary