Catalytic Converter: Service and Repair

REMOVAL
5.7L ENGINE






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(R) Rust Penetrant. Allow 5 minutes for penetration.
3. Remove the clamp (3) holding the LH catalytic converter (4) to the RH catalytic converter (2).
4. If present, grind any tack welds.
5. Remove the catalytic converter-to-manifold bolts (1).
6. Remove the LH catalytic converter (4) from the RH catalytic converter (2).
7. Remove the clamp holding the RH catalytic converter (2) to the exhaust pipe(s).
8. If present, grind tack weld.
9. Remove the RH catalytic converter (2) from the extension pipe.
10. 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
5.7L ENGINE

1. Raise and support the vehicle.
2. Remove any burrs from the RH (2) and LH (4) catalytic converter.
3. Position new RH catalytic converter-to-exhaust pipe clamp on exhaust clamp on exhaust pipe. Insert the RH (2) catalytic converter into the exhaust pipe. Do NOT tighten at this time.
4. Make sure the alignment tang is seated in the alignment slot.
5. Position new RH catalytic cover-to-LH catalytic converter (2). Do not tighten clamp at this time.
6. Make sure the alignment tang is seated in the alignment slot.
7. Install the LH and RH catalytic converters (2 and 4) to the exhaust manifold. Install bolts. Do not tighten at this time.
8. Connect the oxygen sensor electrical connectors.
9. Make sure the catalytic converter assembly (2 and 4) are correctly positioned and properly assigned. The minimum clearance between component is 25 mm (1 inch). Ensure that the exhaust crossover has at least 15 mm (0.59 inch) clearance at transmission crossmember. Ensure that muffler isolators are not stretched. Measurement between insulator rods is approximately 42 mm (1.65 inch). Make the necessary adjustments, if necessary.
10. Tighten manifold flange bolts to 34 Nm (24 ft.lbs). Tighten the new exhaust clamps to 61 Nm (45 ft.lbs).
11. If other sections of the exhaust system where loosened in removal, refer to that information for the tightening procedures.
12. Lower the vehicle.
13. Start the engine, inspect for exhaust leaks. Repair exhaust leaks as necessary.