Dodge ZB 2005, Service Manual

Page: 741 / 1873

INSPECTION
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
Check catalytic converter for a flow restriction.
(Refer to 11 - EXHAUST SYSTEM - DIAGNOSIS
AND TESTING) Exhaust System Restriction Check
for procedure.
Visually inspect the catalytic converter element by
using a borescope or equivalent. Remove oxygen sen-
sor(s) and insert borescope. If borescope is not avail-
able, remove converter and inspect element using a
flashlight. Inspect element for cracked or melted sub-
strate.
NOTE: Before replacing a catalytic converter, deter-
mine the root cause of failure. Most catalytic con-
verter failures are caused by air, fuel or ignition
problems. (Refer to Appropriate Diagnostic Informa-
tion) for test procedures.
INSTALLATION
NOTE: This procedure covers installation of either
the right OR left catalytic converter. Install the
appropriate parts for the side that is being worked
on.
(1) Position catalytic converter to mounting posi-
tion.
(2) Connect resonator to converter. Do not tighten
resonator band clamp at this time to permit align-
ment of all parts.
(3) Loosely install a NEW V-Band clamp at
exhaust manifold to converter pipe connection (Fig.
8).
(4) Loosely install “A” and “B” pillar support isola-
tors (Fig. 8) and (Fig. 11).
(5) Tighten catalytic converter V-Band clamp to 11
N·m (100 in. lbs.) (Fig. 8).
(6) Starting from the front of exhaust system,
align each component to maintain position and
proper clearance with body parts.
(7) Tighten “A” and “B” pillar support isolators to
28 N·m (250 in. lbs.).
(8) Tighten resonator band clamp to 54 N·m (40 ft.
lbs.).
(9) Connect downstream oxygen sensor connector
(Fig. 8) and (Fig. 9).
(10) Install sill panel (Refer to 23 - BODY/EXTE-
RIOR/SILL PANEL - INSTALLATION) (Fig. 7).
(11) Lower vehicle.
(12) Start the engine and inspect for exhaust
leaks. Repair exhaust leaks as necessary.
(13) Check the exhaust system for contact with the
body panels. Make the necessary ajustments, if
needed.
RESONATOR(S)
REMOVAL
NOTE: This procedure covers removal of either the
right OR left resonator. Remove the appropriate
parts for the side that is being worked on.
(1) Raise vehicle on hoist (Refer to LUBRICATION
& MAINTENANCE/HOISTING - STANDARD PRO-
CEDURE).
(2) Remove sill panel (Refer to 23 - BODY/EXTE-
RIOR/SILL PANEL - REMOVAL) (Fig. 7).
(3) Apply penetrating oil to resonator and spout
assembly band clamps (Fig. 10) and (Fig. 11).
(4) Loosen resonator and spout assembly band
clamps (Fig. 10) and (Fig. 11)
(5) Remove “B” pillar support isolator (Fig. 11).
(6) Separate spout assembly from resonator.
(7) Separate resonator from catalytic converter
(Fig. 10).
(8) Remove resonator.
INSTALLATION
NOTE: This procedure covers installation of either
the right OR left resonator. Install the appropriate
parts for the side that is being worked on.
(1) Install resonator to catalytic converter pipe
(Fig. 10). Do not tighten band clamp at this time.
(2) Connect spout assembly to resonator (Fig. 11).
Do not tighten band clamp at this time.
(3) Install “B” pillar support isolator. Tighten bolts
to 28 N·m (250 in. lbs.) (Fig. 11).
(4) Tighten resonator band clamp to 54 N·m (40 ft.
lbs.).
11 - 8 EXHAUST SYSTEM
ZB
CATALYTIC CONVERTER(S) (Continued)