Exhaust System: Service and Repair

REMOVAL AND INSTALLATION





Special Tool(s)

Material:

Material

WARNING: The normal operating temperature of the exhaust system is very high. Never attempt to repair or install any new part of the system until it has cooled. Be especially careful when working around the three-way catalytic converter. The temperature of the three-way catalytic converter rises to a high level after only a few minutes of engine operation.

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

CAUTION: Oil or greased-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. Install the special tool onto the flex pipe.

Part 1 Of 2:

Part 2 Of 2:

3. Remove the parts in the order indicated in the illustration and table.

4. NOTE: Do not tighten the fasteners until all components are assembled. Make sure to tighten all fasteners beginning at the front of the vehicle.

To install, reverse the removal procedure.

5. Check and, if necessary, align the exhaust system.

Item 5: Muffler Assembly Removal Note





1. Using a suitable jack, support the exhaust system.





2. Remove the track bar bolt, then detach the track bar from the body.

Item 7: Flex Pipe Removal Note
1. If unable to remove the flex pipe-to-catalytic converter bolts, carry out the:
^ Remove the head of the bolt by cutting or grinding.
^ Remove the flex pipe assembly.
^ Cut or grind the remaining portion of the bolt at the flange surface. Do not damage gasket surfaces.
^ Center punch the center of the remaining bolt at the flange surface.
^ Drill out the bolt using a 10.5 mm (13/32 inch) drill bit.
^ Clean the mating surfaces of the flex pipe and catalytic converter. Use a service bolt(s), W500035-S439, service flag nut(s) W705839-S441, and a new gasket during installation.

Items 10 and 11: Heated Oxygen Sensor and Catalyst Monitor Sensor Removal Note





1. If installing a new catalytic converter, remove the sensors.

Item 13: Catalytic Converter Removal Note

NOTE: Support the catalytic converter near the rear outlet. Use caution removing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.

NOTE: If necessary, remove the damper.





1. Disconnect the lower catalytic converter bracket.





2. Disconnect the upper catalytic converter bracket.

Item 13: Catalytic Converter Installation Note
1. Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare.
2. Using a suitable jack, support the catalytic converter near the rear outlet. Position the converter to the exhaust manifolds and to the bracket mounting points. Loosely install the lower bracket bolt and upper bracket nut.
3. Install the four new manifold nuts. Do not tighten the nuts at this time.
4. Tighten all the fasteners in the following order:
^ Alternately tighten the manifold nuts at the front exhaust manifold to specification.
^ Alternately tighten the manifold nuts at the rear exhaust manifold to specification.
^ Tighten the upper bracket nut.
^ Tighten the lower bracket bolt.
^ Alternately tighten the new catalytic converter-to-flex pipe bolts to specification.

Items 11 and 10: Catalyst Monitor Sensor and Heated Oxygen Sensor Installation Note
1. Apply anti-seize to the threads of the sensors before installation. Using the special tool, install the sensor.