Exhaust System Replacement

REMOVAL PROCEDURE
1. Raise and suitably support the vehicle.
2. Disconnect the heated oxygen sensor (HO2S) wiring harness connector and retainer.
3. Suitably support the exhaust system.

NOTICE: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

4. Disconnect the exhaust system hanger insulators from the exhaust system.





5. Remove the catalytic converter bolts from the three-way catalytic converter pipe flange.
6. Remove the catalytic converter gasket.





7. Remove the exhaust system.





8. Remove the right (rear) exhaust manifold pipe stud nuts from the exhaust manifold pipe studs.
9. Remove the three-way catalytic converter.
10. Remove the exhaust manifold pipe gasket.





11. Remove the heated oxygen sensor (HO2S).

INSTALLATION PROCEDURE





1. Install the heated oxygen sensor (HO2S).





2. Install a new exhaust manifold pipe gasket.
3. Install the three-way catalytic converter.
4. Install the right (rear) exhaust manifold pipe nuts to the exhaust manifold pipe studs.
^ Tighten the right (rear) exhaust manifold pipe stud nuts to 35 Nm (26 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.





5. Install the exhaust system.

NOTICE: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

6. Connect the exhaust system hanger insulators to the exhaust system.





7. Install a new catalytic converter gasket.
8. Install the catalytic converter bolts through the three-way catalytic converter pipe flange.
^ Tighten the catalytic converter bolts to 45 Nm (33 ft. lbs.).

9. Remove the support from the exhaust system.
10. Connect the heated oxygen sensor (HO2S) wiring harness connector and retainer.
11. Lower the vehicle.
12. Inspect for exhaust system leaks and underbody contact.