Catalytic Converter: Service and Repair
CONVERTER - CATALYTIC5.9L DIESEL ENGINE
WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Remove clamp bolts from exhaust pipe to catalytic converter clamp (5).
NOTE: Do not remove nut from T-Bolt. Only remove nut far enough, so that the T end can be removed from the clamp.
NOTE: The catalytic converter to exhaust manifold clamp is not reusable. Always use a new clamp when reinstalling the catalytic converter.
4. Loosen the nut from clamp (1) at turbocharger.
5. Remove the T bolt end of the fastener, from the clamp (1).
6. Spread the clamp, and remove the catalytic converter (4) and front exhaust pipe (2) from the vehicle.
7. Discard the clamp.
8. Remove front exhaust pipe to catalytic converter clamp (3).
9. Separate front exhaust pipe (2) from catalytic converter (4).
INSTALLATION
NOTE: The catalytic converter to exhaust manifold clamp is not reusable. Always use a new clamp when reinstalling the catalytic converter.
1. Position the catalytic converter (4) onto the front exhaust pipe (2) until the alignment tab is seated into the alignment slot of the catalytic converter (4).
2. Install catalytic converter (4) into the exhaust pipe (6) onto the until the alignment tab is seated into the alignment slot of exhaust pipe (6).
3. Position front exhaust pipe (2) onto turbocharger and install new clamp (1). Tighten the nuts to 11 Nm (100 inch lbs.) torque.
4. Install the exhaust clamp (5) at the exhaust pipe (6) and catalytic converter (5) connection. Tighten the clamp nuts to 54.2 Nm (40 ft. lbs.) torque.
5. 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. Make the necessary adjustments, if needed.
6. Lower the vehicle.
7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.