Dodge Dakota Sport 2001 Service Manual page 1304

AN
CATALYTIC CONVERTER - 2.5L (Continued)
INSTALLATION
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) Align and connect the catalytic converter flange
to the exhaust pipe (Fig. 9).
(2) Install the catalytic converter flange into the
muffler or extension pipe (Fig. 4).
Fig. 4 Extension Pipe/Muffler to Catalytic Converter
1 - CATALYTIC CONVERTER FLANGE
2 - EXTENSION PIPE
(3) If other sections of the exhaust system where
loosened in removal, refer to that information for the
tightening procedures.
(4) At the catalytic converter flange connections,
install the clamp and nuts. Tighten the clamp nuts to
41 N·m (30 ft. lbs.) torque.
(5) Install the crossmember.
(6) Install the rear engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/REAR MOUNT -
INSTALLATION).
(7) Lower the vehicle.
(8) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
Flange
CATALYTIC CONVERTER -
3.9L/5.9L
DESCRIPTION
California emissions vehicles incorporate mini cat-
alytic converters into the exhaust system. These cat-
alytic converters are made of stainless steel designed
to operate at extremely high temperatures.
OPERATION
The catalytic converter captures and burns any
unburned fuel mixture exiting the combustion cham-
bers during the exhaust stroke of the engine. This
process aids in reducing emissions output.
REMOVAL
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 the bolts and nuts with Mopar Rust
Penetrant. Allow 5 minutes for penetration.
(3) Remove the clamp holding the catalytic con-
verter flange to the exhaust pipe(s) (Fig. 3) (Fig. 5).
(4) Remove the clamp holding the catalytic con-
verter flange to the muffler or extension pipe .
(5) Remove the engine rear mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/REAR MOUNT -
REMOVAL).
(6) Remove the crossmember.
(7) Remove the catalytic converter. You may have
to loosen up other sections of the exhaust system.
Fig. 5 Catalytic Converter—3.9L/5.9L Engine
1 - EXHAUST PIPE
2 - CATALYTIC CONVERTER
3 - CLAMP
4 - EXTENSION PIPE TO MUFFLER
EXHAUST SYSTEM 11 - 5