Exhaust System

Exhaust System





Material

Removal

CAUTION: Do not use oil or grease-based lubricants on the isolators. They may cause deterioration of the rubber.

CAUTION: Oil or grease-based lubricants on the isolators may cause the exhaust hanger isolator to separate from the exhaust hanger bracket during vehicle operation.

NOTE: Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. If removing the converter assembly, remove the transmission crossmember.
3. Disconnect the two heated oxygen sensors (HO2S) and the two catalytic monitor electrical connectors.
4. Support the catalytic converter near the rear outlet.





5. Remove and discard the four catalytic converter exhaust flange nuts, then remove and discard the gasket.





6. Loosen the exhaust pipe-to-extension pipe Torca(R) coupling.





7. Loosen the extension pipe-to-muffler Torca coupling.





8. Remove and discard the two muffler rear bracket nuts.
9. Disconnect the three muffler rubber isolators and remove the muffler. Discard the Torca(R) coupling.
10. Disconnect the extension pipe rubber isolator and remove the extension pipe. Discard the Torca(R) coupling.
11. Disconnect the exhaust pipe rubber isolator and remove the exhaust pipe.

12. CAUTION: When removing the catalytic converter, do not damage the manifold outlet flare, the converter inlet flare or the exhaust manifold studs.

Remove the catalytic converter assembly.





13. If installing a new catalytic converter, remove the catalyst monitor sensors.





14. If installing a new catalytic converter, remove the H02S.





15. If necessary, remove the four isolator hangers.





16. If necessary, remove the tail pipe isolator hanger.

Installation





1. If removed, install the tail pipe isolator hanger.





2. If removed, install the four isolator hangers.





3. NOTE: Apply anti-seize to the threads of the H02S before installation.

If installing a new catalytic converter, install the H02S.





4. NOTE: Apply anti-seize to the threads of the catalyst monitor sensor before installation.

If installing a new catalytic converter, install the catalyst monitor sensors.

5. NOTE: Do not tighten the fasteners until all components are assembled.

NOTE: Do not damage the manifold outlet flare, the converter inlet flare or the studs during installation.

Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare. Install the catalytic converter. Support the catalytic converter near the rear outlet.
6. Clean the mating surfaces of the catalytic converter flange and the exhaust pipe flange.
7. Position the exhaust pipe and connect the rubber isolator.





8. NOTE: Do not tighten the fasteners until all components are assembled.

Install a new catalytic converter flange gasket and install four new catalytic converter exhaust flange nuts.
9. Position the extension pipe and connect the rubber isolator.





10. NOTE: Do not tighten the fasteners until all components are assembled.

NOTE: Using a Scotchbrite pad, clean the exhaust clamp surface area of any surface rust.

Place the new clamp on the exhaust pipe-to-extension pipe joint. Make sure the back of the slot is covered by the clamp. The clamp is installed no more than 4 mm (0.16 inch) from the back of the button on the end of the pipe.





11. NOTE: Using a Scotchbrite pad, clean the exhaust clamp surface area of any surface rust.

For vehicles with 139-inch wheelbase or greater, make sure the tab on the exhaust pipe is seated into the notch on the extension pipe.

12. NOTE: Do not tighten the fasteners until all components are assembled.

Position the muffler and connect the rubber isolators. Install the two muffler rear bracket nuts.





13. NOTE: Do not tighten the fasteners until all components are assembled.

NOTE: Using a Scotchbrite pad, clean the exhaust clamp surface area of any surface rust.

Place the new clamp on the extension pipe-to-muffler joint. Make sure the back of the slot is covered by the clamp. The clamp is installed no more than 4 mm (0.16 inch) from the back of the button on the end of the pipe.





14. Make sure the tab on the extension pipe is seated into the notch on the muffler inlet pipe.
15. Align the exhaust system.





16. To seat the catalytic converter, tighten the catalytic converter nuts in the following sequence:
^ Tighten the LH lower converter nut to 20 Nm (15 ft. lbs.).
^ Tighten the LH upper converter nut to 40 Nm (30 ft. lbs.).
^ Tighten the LH lower converter nut to 40 Nm (30 ft. lbs.).





17. To seat the catalytic converter, tighten the catalytic converter nuts in the following sequence:
^ Tighten the RH lower converter nut to 20 Nm (15 ft. lbs.).
^ Tighten the RH upper converter nut to 40 Nm (30 ft. lbs.).
^ Tighten the RH lower converter nut to 40 Nm (30 ft. lbs.).
18. Tighten the four catalytic converter exhaust flange nuts.





19. Tighten the exhaust pipe-to-extension pipe Torca(R) coupling.





20. Tighten the extension pipe-to-muffler Torca(R) coupling.





21. Tighten the two muffler rear bracket nuts.
22. Connect the two HO2S and the two catalytic monitor electrical connectors.
23. If removed, install the transmission crossmember.