Repair Procedure
REPAIR PROCEDUREWARNING:
As with all exhaust system repairs, please carry out each step with special attention towards avoiding exhaust leakage that might cause deadly carbon monoxide to escape at any point under the vehicle.
NOTE:
Be sure to follow the repair procedure, otherwise, the symptom will recur.
CAUTION:
DO NOT USE "NEVER-SEEZ" PRODUCT ON CAL. SPEC. VEHICLES.
1. Verify customer concern.
2. Safely lift vehicle on hoist.
3. Remove seal ring from exhaust manifold.
4. Stuff a cloth into exhaust manifold and catalytic converter to prevent dust or debris from entering.
5. Spray parts cleaner to exhaust manifold-to-seal ring installation position, and round surface of catalytic converter-side flared flange. Let it sit for 2 3 minutes.
6. Using sandpaper (#80 - #400), polish flared portion of catalytic converter and seal ring installed location in exhaust manifold until bare metal is exposed.
NOTE:
Make sure the polished surface is free from seal ring residue, debris, or wear marks.
7. Run your finger over seal ring installed location (flange) of exhaust manifold. If surface feels rough, use #80 sandpaper until rough surface is gone, then use fine sandpaper until bare metal is exposed.
NOTE:
Do not use air tools.
8. If severe damage appears on round surface of catalytic converter-side flared flange, replace catalytic converter.
NOTE:
If the catalytic converter is replaced and a black coating remains on the round surface of the flared flange, the white coating of the seal ring will stick to the black coating, which may cause noise. Be sure to sufficiently polish the flange.
9. Using a piece of cloth including organic solvent (acetone, methanol) or a piece of cloth free of oil content, wipe off any debris or grease from polished area.
10. Remove cloth from exhaust manifold.
NOTE:
During cloth removal, be careful not to allow any foreign substances into the pipe.
11. Push new seal ring onto manifold flange by hand.
NOTE:
^ Make sure seal ring fits straight and does not fall off when you remove your hand from the ring.
^ Make sure seal ring fits straight, and does not fall off when you remove your hand from the ring.
^ Make sure seal ring fits straight, if not, there is a possibility the lubrication on the inner surface will be damaged when the seal ring is press-fitted with the special service tool.
12. Seat seal ring by lightly tapping end of special service tool with a rubber hammer.
13. Push in seal ring until edge of it contacts flange.
14. Re-assemble exhaust system.
CAUTION:
DO NOT USE "NEVER-SEEZ" PRODUCT ON CAL. SPEC. VEHICLES.
15. Verify repair.
WARNING:
Exhaust leaks can allow carbon monoxide into the vehicle and cause injury or death, please go over the system and be sure there are no gas leaks at any point before returning the vehicle to the customer.
If Catalytic Converter Has Been Replaced:
1. Using new springs, temporarily assemble catalytic converter with manifold.
NOTE:
Do not allow any damage on the round surface of the flare and seal ring.
2. Install hanger rubber in rear side of catalytic converter.
3. Tighten catalytic converter and manifold together.
Tightening Torque: 38 - 51 Nm (28.0 - 37.6 ft. lbs.)
4. Insert middle pipe into catalytic converter.
5. Temporarily assemble middle pipe and main silencer.
6. Install hanger rubber in rear end of middle pipe.
7. Tighten middle pipe and main silencer together.
Tightening Torque: 38 - 51 Nm (28.0 - 37.6 ft. lbs.)
8. Make sure middle pipe has been inserted until it reaches catalytic converter stopper, then tighten.
Tightening Torque: 40 - 54 Nm (29.5 - 39.8 ft. lbs.)
9. Verify repair and check exhaust system routing.
WARNING:
Exhaust leaks can allow carbon monoxide into the vehicle and cause injury or death, please go over the system and be sure there are no gas leaks at any point before returning the vehicle to the customer.
If Catalytic Converter Has Not Been Replaced:
1. With catalytic converter and middle pipe assembled, temporarily tighten them using new springs.
NOTE:
Do not allow any damage on the round surface of the flare and seal ring.
2. Install hanger rubber in rear end of catalytic converter.
3. Tighten catalytic converter and manifold together.
Tightening Torque: 38 - 51 Nm (28.0 - 37.6 ft. lbs.)
4. Temporarily assemble middle pipe and main silencer.
5. Install hanger rubber in rear end of middle pipe.
6. Tighten middle pipe and main silencer together.
Tightening Torque: 38 - 51 Nm (28.0 - 37.6 ft. lbs.)
7. Verify repair and check exhaust system routing.
WARNING:
Exhaust leaks can allow carbon monoxide into the vehicle and cause injury or death, please go over the system and be sure there are no gas leaks at any point before returning the vehicle to the customer.