Catalytic Converter: Service and Repair
CATALYTIC CONVERTERREMOVAL
2.8L 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 the nuts from the front exhaust pipe and catalytic converter to muffler flange.
NOTE: The front exhaust pipe and catalytic converter to turbocharger clamp is not reusable. Always use a new clamp when reinstalling the catalytic converter.
4. Remove the nut from the front exhaust pipe and catalytic converter to turbocharger clamp (1). Spread the clamp.
5. Lower the catalyst assembly (2) and slide out of the mount at the transmission (if equipped).
6. Remove the front exhaust pipe/catalytic converter assembly from the vehicle.
7. Discard the front exhaust pipe and catalytic converter to turbocharger clamp (1). Discard clamp.
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
1. Position new turbocharger to front exhaust pipe and catalytic converter clamp (1) on turbocharger.
2. Position the front exhaust pipe and catalytic converter assembly (2) into the mount at the transmission (if equipped) and onto the turbocharger.
3. Install the nuts at the front exhaust pipe and catalytic converter assembly to muffler flange. Do not tighten.
4. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 inch) is required.
5. Tighten turbocharger to front exhaust pipe and catalytic converter assembly clamp nut to 27 Nm (19 ft. lbs.) torque.
6. Install the bolts at the front exhaust pipe and catalytic converter assembly (2) to muffler flange.. Tighten the nuts to 27 Nm (19 ft. lbs.) torque.
7. Lower the vehicle.
8. Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary.
9. Check the exhaust system for contact with the body panels. Make adjustments, if necessary.