Service Procedure
SERVICE PROCEDURE VIDEOTAPENo videotape of the service procedure for this recall will be provided.
Service Procedure
A. REPLACE OXYGEN SENSOR:
1. Raise vehicle on hoist.
2. Locate oxygen sensor in the exhaust "Y" pipe before the catalytic converter as shown in Figure 1.
3. Disconnect oxygen sensor connector.
4. Remove oxygen sensor.
5. Clean threads in exhaust pipe with a thread chaser.
Note:
Do not use solvents or lubricants on threads.
6. Install provided oxygen sensor. Tighten to 22 ft lbs (30 Nm).
7. Connect oxygen sensor connector.
B. REPLACE CATALYTIC CONVERTER:
Warning:
If torches are used when working on the exhaust system, do not allow the flame near the plastic fuel lines.
1. Remove and discard the nuts, bolts and gasket at the front of the converter and the exhaust pipe clamp at the rear (Figure 2).
Note:
Use penetrating oil if necessary.
2. Insert a chisel-tipped tool between the converter and intermediate pipe connection and loosen the converter from the pipe.
Note:
Do not damage the intermediate pipe as it must be reused.
3. Place a block of wood against the rear of the converter and drive the converter forward to disengage the alignment tab on the converter pipe from the alignment slot on the intermediate pipe.
Note:
If the converter does not move forward, it may be necessary to heat the converter to intermediate pipe connection with an oxyacetylene torch until the metal becomes cherry red.
4. Twist the converter back and forth to separate it from the intermediate pipe.
5. Install the new converter into the intermediate pipe until the alignment tab is inserted into the alignment slot.
6. Using the provided gasket, nuts and bolts, attach the converter to the front exhaust pipe. Do not tighten the bolts.
7. Install and tighten the new exhaust pipe clamp, at the intermediate pipe to converter connection, to 40 ft lbs.
8. Tighten the converter to front exhaust pipe bolts to 25 ft lbs.
9. Lower vehicle
C. INSTALL RECALL COMPLETION LABEL:
1. With a ball point pen, print your dealer code (5 digits) on the supplied Recall Completion Label.
2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label on the underside of the hood.
D. COMPLETE PROOF OF CORRECTION FORM:
1. Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner.