Catalytic Converter Replacement (LGH /LML)

Catalytic Converter Replacement (LGH /LML)

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Remove the transmission 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)).




3. Disconnect the engine harness connector (1), the emission reduction fluid injector connector (2), and the temperature sensor from the catalytic converter.




4. Remove the catalytic converter to diesel particulate filter nuts (3).




5. Loosen the turbocharger exhaust pipe-to-catalytic converter clamp (1).




6. Remove the exhaust hanger bracket bolt (1) and bracket stud (2).
7. With the catalytic converter exhaust isolator attached, lower the catalytic converter with the exhaust bracket (3).
8. If replacing catalytic converter, transfer the exhaust isolator and the exhaust temperature sensor.

Installation Procedure

1. If replacing the catalytic converter, apply water based lubricant to the exhaust isolator for ease of installation.




2. Position the catalytic converter to the turbocharger exhaust outlet pipe.
3. Position the catalytic converter with the exhaust bracket (3) to the engine.

Caution: Refer to Fastener Caution (Fastener Caution).

4. Tighten the bolt (1) and stud (2) to 25 Nm (18 lb ft).




5. Install a NEW catalytic converter to diesel particulate filter gasket.
6. Install the catalytic converter to particulate filter nuts (3) until snug.





Note: Ensure that the manifold pipe is square to the exhaust pipe adapter.

7. Slide the exhaust pipe clamp (1) down and around the pipe connection.
8. Tighten the exhaust pipe clamp to 12 Nm (106 lb in).




9. Tighten the catalytic to diesel particulate filter nuts (1) to 45 Nm (33 lb ft).




10. Connect the emission reduction fluid injector connector (2) and the engine harness connector (1).
11. Install the transmission 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)).
12. Lower the vehicle.
13. Start the engine and check for leaks.