Catalytic Converter - Underbody
Catalytic Converter - Underbody
Removal
NOTICE: Do not use oil or grease-based lubricants on the insulators. They may cause deterioration of the rubber.
NOTICE: Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation.
NOTE: The production catalytic converter and muffler assembly is a 1-piece construction. The service catalytic converter and muffler is a 2-piece construction.
NOTE: If replacement is not required, the production catalytic converter and muffler assembly can be removed and installed as one piece. It is only necessary to cut the production exhaust to enable the service section to be fitted. Before cutting any part of the exhaust system, check that the position of the cut is correct in comparison to the service section being installed.
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.
2.5L vehicles
2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
All vehicles
3. NOTICE: Only use hand tools when removing or installing the spring nuts or damage may occur to the exhaust intermediate pipe/exhaust Y-pipe flange studs.
NOTE: When loosening the exhaust intermediate pipe/exhaust Y-pipe spring nuts, alternately loosen the nuts from side to side.
Remove and discard the two 10-mm exhaust catalytic converter-to-exhaust intermediate pipe/exhaust Y-pipe spring nuts.
4. NOTICE: Only use hand tools when removing or installing the spring nuts or damage may occur to the resonator flange studs.
NOTE: When loosening the resonator spring nuts, alternately loosen the nuts from side to side.
Remove and discard the two 8-mm resonator-to-muffler spring nuts.
5. NOTICE: Remove the gaskets by simultaneously pulling up and twisting the gasket on the pipe. Do not pry under the gasket or damage to the flange may occur.
Detach the 3 exhaust hangers and remove the catalytic converter and muffler assembly.
- Remove and discard the gaskets.
2.5L vehicles
6. Cut the exhaust system as indicated in illustration.
3.0L vehicles
7. Cut the exhaust system as indicated in illustration.
2.5L hybrid vehicles
8. Cut the exhaust system as indicated in illustration.
Installation
NOTICE: The exhaust hanger insulators are constructed of a special material. Use only the correct specification exhaust hanger insulator or damage to the exhaust system may occur.
NOTE: Check the exhaust hanger insulators for damage and fatigue. Install new exhaust hanger insulators as required.
NOTE: Thoroughly clean the sealing surfaces of the flanges using a finishing pad.
1. NOTE: Do not tighten the service clamp at this time.
Install the service clamp onto the catalytic converter section.
2. Install the catalytic converter section and service clamp onto the muffler section.
3. Inspect the exhaust intermediate pipe/exhaust Y-pipe and resonator flange studs for damage.
- If damaged, replace stud(s), or if stud comes out when removing nut(s), replace the stud(s).
NOTE: If replacement of the exhaust intermediate pipe/exhaust Y-pipe flange stud(s) is required, perform Steps 4 and 5.
4. Use the C-Frame and Screw Installer/Remover to push the 10-mm stud out of the flange.
5. NOTE: When positioning the new 10-mm stud in the exhaust intermediate/exhaust Y-pipe flange, make sure to line up the new stud seat knurls with witness knurl grooves in the exhaust intermediate/exhaust Y-pipe flange.
Use a C-clamp and a deep-well socket to push the 10-mm stud fully into the flange.
- Make sure the stud is fully and evenly seated into the flange.
NOTE: If replacement of the resonator flange stud(s) is required, perform Steps 6 and 7.
6. Use the C-Frame and Screw Installer/Remover to push the 8-mm stud out of the flange.
7. NOTE: When positioning the new 8-mm stud in the resonator flange, make sure to line up the new stud seat knurls with witness knurl grooves in the resonator flange.
Use a C-clamp and a deep-well socket to push the 8-mm stud fully into the flange.
- Make sure the stud is fully and evenly seated into the flange.
8. NOTE: Do not tighten the service clamp at this time.
Attach the catalytic converter and muffler assembly to the 3 exhaust hangers.
9. NOTICE: Replace the gasket by hand. Do not rotate the gasket back and forth during installation. Doing so may lessen the gaskets ability to seal and stay correctly positioned during assembly.
NOTE: Thoroughly clean the sealing surfaces of the flanges using a finishing pad. Inspect the cleaned sealing surface for nicks and scratches and replace as necessary.
Install a new resonator-to-muffler gasket by hand.
10. Install the 2 new 8-mm resonator-to-muffler spring nuts and alternately tighten RH side to LH side in sequence in 3 stages:
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 10 Nm (89 lb-in).
- Stage 3: Tighten to 17 Nm (150 lb-in).
11. NOTICE: Replace the gasket by hand. Do not rotate the gasket back and forth during installation. Doing so may lessen the gaskets ability to seal and stay correctly positioned during assembly.
NOTE: Thoroughly clean the sealing surfaces of the flanges using a finishing pad. Inspect the cleaned sealing surface for nicks and scratches and replace as necessary.
Install a new converter-to-exhaust intermediate/exhaust Y-pipe gasket by hand.
12. Install the 2 new 10-mm catalytic converter-to-exhaust intermediate/exhaust Y-pipe spring nuts and alternately tighten RH side to LH side in sequence in 3 stages:
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 15 Nm (133 lb-in).
- Stage 3: Tighten to 25 Nm (18 lb-ft).
13. Tighten the 4 service clamp nuts to 47 Nm (35 lb-ft).