Catalytic Converter Replacement (L96 with ZW9)

Catalytic Converter Replacement (L96 with ZW9)

Removal Procedure

Warning: Refer to Exhaust Service Warning (Service Precautions).

Warning: Refer to Hot Exhaust System Warning (Hot Exhaust System Warning).

1. Disconnect the heated oxygen sensor (HO2S). Refer to the following:

* Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (2500 Series - Cab/Chassis) ()Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (2500 Series) ()Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) ()
* Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (2500 Series - Cab/Chassis) ()Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (2500 Series) ()Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (1500 Series) ()
* Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) ()
* Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series - Cab/Chassis) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series) ()

2. Support the transmission with a suitable transmission jack.
3. Remove the transmission support crossmember. Refer to Transmission Support Crossmember Replacement (2WD 1500 Series) (Transmission Support Crossmember Replacement (2WD 1500 Series))Transmission Support Crossmember Replacement (4WD 1500 Series) (Transmission Support Crossmember Replacement (4WD 1500 Series))Transmission Support Crossmember Replacement (2WD 2500/3500 Series) (Transmission Support Crossmember Replacement (2WD 2500/3500 Series))Transmission Support Crossmember Replacement (4WD 2500/3500 Series) (Transmission Support Crossmember Replacement (4WD 2500/3500 Series))




4. Remove the exhaust muffler nuts (1) from the catalytic converter (3).
5. Remove the exhaust muffler isolator rod (2) from the exhaust isolator.




6. Remove the exhaust manifold pipe to exhaust manifold nuts (1) and discard the seal (2).




7. Remove the right catalytic converter (3) and seal (2), from the exhaust manifold with the bolts (1).




8. Separate the catalytic converter hanger rod (1) from the exhaust isolator.
9. With the aid of an assistant, lower the catalytic converter (2) from the vehicle.
10. If replacing the catalytic converter, transfer the oxygen sensors.

Installation Procedure




1. Install the catalytic converter hanger rod (1) into the exhaust isolator.





Caution: Refer to Fastener Caution (Fastener Caution).

2. Install a NEW seal (2) to the left manifold exhaust pipe. Tighten the nuts (1) to 50 Nm (37 lb ft).




3. Inspect the seal (2) and replace if worn or damaged.
4. Install the right catalytic converter to the exhaust manifold with nuts (1) and tighten to 50 Nm (37 lb ft).




5. Instal the exhaust muffler hanger rod (2) into the exhaust isolator.
6. Install the exhaust muffler to catalytic converter (3) with the nuts (1) and tighten to 45 Nm (33 lb ft).
7. Install the transmission support crossmember. Refer to Transmission Support Crossmember Replacement (2WD 1500 Series) (Transmission Support Crossmember Replacement (2WD 1500 Series))Transmission Support Crossmember Replacement (4WD 1500 Series) (Transmission Support Crossmember Replacement (4WD 1500 Series))Transmission Support Crossmember Replacement (2WD 2500/3500 Series) (Transmission Support Crossmember Replacement (2WD 2500/3500 Series))Transmission Support Crossmember Replacement (4WD 2500/3500 Series) (Transmission Support Crossmember Replacement (4WD 2500/3500 Series))
8. Remove the support from the transmission.
9. Connect the HO2S sensors. Refer to the following:

* Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (2500 Series - Cab/Chassis) ()Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (2500 Series) ()Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (1500 Series) ()
* Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (2500 Series - Cab/Chassis) ()Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (2500 Series) ()Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 (1500 Series) ()
* Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) ()
* Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series - Cab/Chassis) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series) ()

10. Start the engine and check the front exhaust system for leaks.