Dodge Ram Truck 1500-2500-3500. Manual — part 1430

SPECIAL TOOLS

TURBOCHARGER TESTER 9022

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EXHAUST SYSTEM

DR/DH

CONVERTER-CATALYTIC

DESCRIPTION

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THERE-
FORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT
IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER.
THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE
OPERATION TIME.

CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure
of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing
through the converter.

The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in
bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the con-
verter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time
the converter is replaced. Also, inspect all other components of the exhaust system for heat damage.

Unleaded gasoline must be used to avoid contaminating the catalyst core.

50 State emission vehicles incorporate two mini catalytic converters located after the exhaust manifolds and before
the inline catalytic converter.

OPERATION

The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the
exhaust stroke of the engine. This process aids in reducing emissions output.

REMOVAL

3.7L/4.7L ENGINE

1. Raise and support vehicle.

2. Saturate the bolts and nuts with heat valve lubri-

cant. Allow 5 minutes for penetration.

3. Disconnect oxygen sensor electrical connectors.

4. Remove clamps (3 and 5) and nuts.

5. Remove LH catalytic converter (7) to exhaust man-

ifold bolts (2).

6. Remove LH catalytic converter (7).

7. Remove RH catalytic converter ( 3) to exhaust

manifold bolts (2).

8. Remove RH catalytic converter (3).

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EXHAUST SYSTEM

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5.7L ENGINE

1. Raise and support vehicle.

2. Saturate the bolts and nuts with heat valve lubri-

cant. Allow 5 minutes for penetration.

3. Disconnect oxygen sensor electrical connectors.

4. Remove clamps and nuts (4).

5. Remove catalytic converter to exhaust manifold

bolts (2) and nuts (1).

6. Remove catalytic converter assembly (3).

5.9L DIESEL ENGINE

WARNING: IF TORCHES ARE USED WHEN WORK-
ING 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 lubri-

cant. 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).

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EXHAUST SYSTEM

DR/DH

8.3L ENGINE

1. Raise and support vehicle.

2. Saturate the bolts and nuts with heat valve lubri-

cant. Allow 5 minutes for penetration.

3. Disconnect oxygen sensor electrical connectors.

4. Remove LH exhaust pipe to manifold bolts (2),

retainers and nuts (1).

5. Remove LH catalytic converter to muffler clamp

nuts (4).

6. Rotate LH catalytic converters (6) from the muffler

(5).

7. Remove RH exhaust pipe to manifold bolts (2),

retainers and nuts (1).

8. Remove RH catalytic converter to muffler clamp

nuts (4).

9. Rotate RH catalytic converter (3) from the muffler

(5).

10. Remove clamps and nuts (4).

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

3.7L/4.7L ENGINE

1. Install RH catalytic converter to exhaust clamp (4)

on RH catalytic converter (3) and position into
exhaust pipe (5).

2. Install and hand tighten RH catalytic converter to

exhaust manifold bolts (1).

3. Install LH catalytic converter to RH catalytic con-

verter clamp (6) on RH catalytic converter (3).

4. Position LH catalytic converter (7) into RH catalytic

converter (3).

5. Install and hand tighten LH catalytic converter to

exhaust manifold bolts (1).

6. Tighten catalytic converter to exhaust manifold

bolts (1) to 31 N·m (23 ft. lbs.).

7. Tighten all clamp nuts (4 and 6) to 52.2 N·m (40 ft.

lbs.) torque.

8. Check the exhaust system for contact with the

body panels. A minimum of 25.4 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, if needed.

9. Lower the vehicle.

10. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.

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EXHAUST SYSTEM

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