Catalytic Converter: Service and Repair

Exhaust System:

REMOVAL
1. Disconnect battery ground cable .

NOTE: When battery voltage is removed from the Powertrain Control Module (PCM), all learned values will be cleared and reset to predetermined values. When battery voltage is restored to the PCM, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveablilty and performance.

2. Raise and support vehicle.
3. Disconnect rear Heated Oxygen Sensor (HO2S) electrical connector.
4. Use Oxygen Sensor Wrench T94P-9472-A to remove rear HO2S.
5. Remove the two muffler-to-converter bolts.
6. Loosen and remove the exhaust manifold-to-Y pipe nuts. Slide flexible link, muffler and muffler outlet pipe rearward. Remove the gasket. Move the dual converter Y pipe rearward. Rotate to clear studs and remove.

INSTALLATION
1. Install dual converter Y pipe onto exhaust manifold studs and loosely secure in place with exhaust manifold-to-Y pipe nuts.
2. Install a new non-asbestos gasket between three way catalytic converter and muffler. Secure flange gasket with two nuts. Tighten to 34-46 Nm (25-34 lb.ft.).
3. Secure muffler to exhaust converter frame bracket . Tighten nuts to 25-35 Nm (18-26 lb.ft.).
4. Tighten exhaust manifold connections by alternating the tightening of the manifold bolts or nuts to 34-46 Nm (25-34 lb.ft.).
5. Use Oxygen Sensor Wrench T94P-9472-A to install rear HO2S.
6. Connect rear HO2S electrical connector.
7. Connect battery ground cable.