Exhaust Pipe: Service and Repair

Exhaust Y-Pipe - Dual Catalytic Converter

Special Tool(s):

Material:

Removal and Installation

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 3-way catalytic converter. The temperature of the 3-way catalytic converter rises to a high level after only a few minutes of engine 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. For additional information, refer to Maintenance/Service and Repair.

2. CAUTION: Use caution removing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.

Support the exhaust Y-pipe-dual catalytic converter near the rear outlet.
3. Disconnect the 2 Torca clamps.
^ To install, tighten to 47 Nm (35 ft. lbs.).
4. Disconnect the 2 heated oxygen sensor (HO2S) electrical connectors.
5. Disconnect the 2 catalyst monitor sensor (CMS) electrical connectors.
6. Remove the 4 manifold-to-exhaust Y-pipe-dual catalytic converter flange stud nuts and the converter assembly.
^ To install, tighten to 40 Nm (30 ft. lbs.).





7. If necessary, using the special tool, remove the 2 CMS.

^ NOTE: Apply anti-seize to the sensor threads before installation.

To install, tighten to 41 Nm (30 ft. lbs.).





8. If necessary, using the special tool, remove the 2 HO2S.

^ NOTE: Apply anti-seize to the sensor threads before installation.

To install, tighten to 41 Nm (30 ft. lbs.).
9. If necessary, remove the manifold-to-exhaust Y-pipe-dual catalytic converter flange studs.
^ To install, tighten to 40 Nm (30 ft. lbs.).
10. To install, reverse the removal procedure.

11. NOTE: Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare. Support the catalytic converter near the rear outlet. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs. To correctly seat the converter, alternately tighten the exhaust manifold-to-exhaust Y-pipe dual catalytic converter nuts to specification.

Check and, if necessary, align the exhaust system. For additional information, refer to Exhaust System Alignment.