Catalytic Converter: Service and Repair

WARNING: The Normal operating temperature of the exhaust system is very high. Never attempt to service any part of the system until it has cooled. Be especially careful when working around the catalytic converter. The temperature of the converter rises to a high level after only a few minutes of engine operation.

CAUTION: When servicing exhaust system or removing exhaust components, disconnect all heated oxygen sensors at the wiring connectors to prevent damage to the heated oxygen sensors and wiring harness.

Exhaust System:

REMOVAL
1. Raise vehicle.
2. Disconnect heated oxygen sensors at wiring harness connectors.
3. Remove two nuts retaining the muffler inlet flange to the muffler inlet pipe flange.
4. Disengage muffler flange from muffler inlet pipe flange studs.
5. Remove four nuts retaining dual converter Y pipe flanges to the exhaust manifolds.
6. Slide dual converter Y pipe rearward to disconnect dual converter Y pipe from exhaust outlet pipe frame bracket. Remove dual converter Y pipe.
7. Remove muffler inlet pipe from dual converter Y pipe by loosening muffler clamp and pulling muffler inlet pipe from dual converter Y pipe.

INSTALLATION
1. Slide muffler inlet pipe over dual converter Y pipe so the dual converter Y pipe is bottomed into muffler inlet pipe. Position exhaust clamp and tighten to 34-46 Nm (26-33 lb ft).
2. Engage dual converter Y pipe to exhaust outlet pipe frame bracket. Slide dual converter Y pipe forward.
3. Position dual converter Y pipe flanges to exhaust manifolds and install new retaining nuts. Do not tighten nuts at this time
4. Align dual converter Y pipe to conform to clearance specification.
5. Tighten all exhaust manifold nuts to 24-31 Nm (18-22 lb ft).
6. Position LH exhaust shield to dual converter Y pipe and tighten retaining bolts to 8-10 Nm (71-88 lb in) and 5-6 Nm (44-53 lb in).
7. With muffler supported by exhaust outlet pipe frame brackets, install muffler inlet flange over muffler inlet pipe flange studs. Install, but do not tighten, retaining nuts.
8. Align muffler.
9. Tighten flange nuts to 30-40 Nm (23-29 lb ft).
10 Connect heated oxygen senors to wiring harness connectors
11. Lower the vehicle.