Exhaust System: Service and Repair

Exhaust System Replacement

Removal Procedure





Servicing of the catalytic converter, resonator or pipe requires the replacement of the exhaust system as a complete one-piece unit.

Caution: Refer to Hot Exhaust System Caution in Service Precautions.

Caution: Refer to Exhaust Parts Removal Caution in Service Precautions.

1. Raise and support the vehicle. Refer to Vehicle Lifting.

Caution: Eye protection must be worn when drilling rivets to reduce the chance of personal injury.

2. Drill through the center of the oxygen sensor wiring harness heat shield rivets.
3. Remove the heat shield (2) from the floor panel.
4. Remove the oxygen sensor retainer (1) from the heat shield (2).
5. Disconnect the heated oxygen sensor at the pigtail.
6. Remove the heated oxygen sensor if replacement is necessary.





7. Remove the four nuts securing the catalytic converter to the rear exhaust manifold pipe.
8. Remove the catalytic converter gasket. Do not reuse the gasket.
9. Suitably support the exhaust system.





10. Remove the two bolts securing the center exhaust hangers to the rear suspension support brackets.





11. Remove the two bolts securing the rear exhaust hanger brackets to the rear compartment rails.
12. With the aid of an assistant, Lower the exhaust system.





13. Remove the two nuts securing the rear exhaust hangers to the rear exhaust hanger brackets.
14. Remove the rear exhaust hanger brackets from the rear exhaust hangers.

Installation Procedure





1. Install the rear exhaust hanger brackets to the rear exhaust hangers.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the two nuts securing the rear exhaust hangers to the rear exhaust hanger brackets.
^ Tighten the rear exhaust hanger nuts to 30 Nm (22 ft. lbs.).





Notice: Refer to Exhaust System Clearance Notice in Service Precautions.

3. Place a NEW catalytic converter gasket over the catalytic converter studs.

Notice: Refer to Flex Decoupler Joint/Mounting Position Notice in Service Precautions.

4. With the aid of an assistant, raise the exhaust system into position, aligning the catalytic converter with the rear exhaust manifold pipe.
5. Finger tighten the four nuts to the catalytic converter studs.





6. Install the two bolts securing the rear exhaust hanger brackets to the rear compartment rails.
^ Tighten the rear exhaust hanger bolts to 50 Nm (37 ft. lbs.).





7. Install the two bolts securing the center exhaust hangers to the rear suspension support brackets.
^ Tighten the center exhaust hanger bolts to 30 Nm (22 ft. lbs.).
8. Tighten the four catalytic converter nuts previously installed in step 5.
^ Tighten the catalytic converter nuts to 25 Nm (18 ft. lbs.).
9. Install the heated oxygen sensor.





10. Install the oxygen sensor retainer (1) to the heat shield.
11. Position the oxygen sensor wiring harness heat shield (2) to the floor panel, aligning the holes.
12. Using a rivet gun, fasten both the oxygen sensor wiring harness heat shield (2) and the catalytic converter heat shield to the floor panel with a single rivet (3).
13. Install the remaining rivets.
14. Lower the vehicle.