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Exhaust Y-Pipe - Dual Catalytic Converter




Exhaust Y-Pipe - Dual Catalytic Converter

Removal

All vehicles

NOTICE: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation.

NOTE: The exhaust Y-pipe dual catalytic converter is a 2-piece assembly. The RH and LH converters can be serviced separately as needed.

1. With the vehicle in NEUTRAL, position it on a hoist.

3.5L Gasoline Turbocharged Direct Injection (GTDI)

2. Disconnect the LH Heated Oxygen Sensor (HO2S) pushpin and electrical connector.

All vehicles

3. If equipped, release the 4 fasteners and remove the splash shield.





3.5L GTDI (Gasoline Turbocharged Direct Injection)

4. Disconnect the RH HO2S (Heated Oxygen Sensor) pushpin and electrical connector.

3.7L, 5.0L and 6.2L

5. Disconnect the 2 HO2S (Heated Oxygen Sensor) pushpins and electrical connectors.

All vehicles

6. Disconnect the 2 Catalyst Monitor Sensor (CMS) electrical connectors.

7. Loosen the RH catalytic converter-to-LH catalytic converter Torca(R) clamp.





8. Remove and discard the 2 LH catalytic converter-to-exhaust manifold or turbocharger nuts.





9. Remove the LH catalytic converter from the vehicle.

Four-Wheel Drive (4WD) vehicles

10. If equipped, remove the 4 bolts and the transfer case skid plate.





All vehicles

11. Using an appropriate tool, support the transmission.

12. NOTE: LH side shown, RH similar.
Remove the 2 heat shield bolts from the transmission crossmember.






13. Remove the 2 transmission insulator and retainer/exhaust support bracket assembly nuts.

14. Remove the 4 transmission crossmember nuts, the 4 bolts and remove the transmission crossmember from the vehicle.

15. Remove the LH isolator cap from the transmission insulator and retainer/exhaust support bracket assembly.





4WD (Four-Wheel Drive) vehicles

16. Remove the 4 transmission insulator and retainer/exhaust support bracket assembly bolts and remove the transmission insulator and retainer/exhaust support bracket assembly from the vehicle.





2-Wheel Drive (2WD) vehicles

17. Remove the 3 transmission insulator and retainer/exhaust support bracket assembly bolts and remove the transmission insulator and retainer/exhaust support bracket assembly from the vehicle.





3.5L GTDI (Gasoline Turbocharged Direct Injection) and 3.7L vehicles

18. NOTICE: Do not excessively bend, twist or allow the exhaust intermediate pipe to hang from the flexible pipe or damage to the muffler and tailpipe may occur.
Support the exhaust intermediate pipe with a jackstand.


All vehicles

19. Remove the 2 RH catalytic converter-to-exhaust intermediate pipe bolts.

20. With help of an assistant, remove the 2 nuts on the RH catalytic converter-to-exhaust manifold or turbocharger joint and remove the RH catalytic converter from the vehicle.
- Discard the nuts.






Installation

NOTE: Clean the mating surfaces of the exhaust manifold outlet or turbocharger flares and the catalytic converter inlet flares.

All vehicles

1. With the help of an assistant, position the RH catalytic converter into the vehicle and loosely install 2 new RH catalytic converter-to-exhaust manifold or turbocharger nuts.





2. NOTICE: If equipped, do not excessively bend, twist or allow the exhaust to hang from the flexible pipe or damage to the muffler and tailpipe may occur.
Loosely install the 2 RH catalytic converter-to-intermediate pipe bolts.


2WD (2-Wheel Drive) vehicles

3. Install the transmission insulator and retainer/exhaust bracket assembly and 3 bolts.
- Tighten to 90 Nm (66 lb-ft).






4. Install the transmission crossmember, 4 bolts and 4 nuts.
- Tighten to 90 Nm (66 lb-ft).






5. Lower the transmission onto the transmission crossmember and install the 2 transmission insulator and retainer/exhaust support bracket assembly nuts.
- Tighten to 103 Nm (76 lb-ft).






4WD (Four-Wheel Drive) vehicles

6. Loosely install the transmission insulator and retainer/exhaust support bracket assembly and the 4 bolts.





7. Position the transmission crossmember and loosely install the 2 transmission insulator and retainer/exhaust support bracket assembly nuts.





8. Install the 4 transmission crossmember bolts and nuts.
- Tighten the transmission insulator and retainer/exhaust support bracket assembly and 4 bolts to 90 Nm (66 lb-ft).

- Tighten the transmission crossmember bolts and nuts to 90 Nm (66 lb-ft).

- Tighten the 2 transmission insulator and retainer/exhaust support bracket assembly nuts to 103 Nm (75 lb-ft).






All vehicles

9. Loosely install the LH isolator cap and bolt onto the transmission insulator and retainer/exhaust support bracket assembly.





10. NOTE: LH side shown, RH similar.
Install the 2 heat shield bolts into the transmission crossmember.

- Tighten to 15 Nm (133 lb-in).






4WD (Four-Wheel Drive) vehicles

11. If equipped, install the transfer case skid plate and 4 bolts.
- Tighten to 24 Nm (18 lb-ft).






All vehicles

12. Slide the LH catalytic converter into the RH catalytic converter up to the stop on the LH catalytic converter and position the LH catalytic converter into place.





13. Loosely install the 2 new LH catalytic converter-to-exhaust manifold or turbocharger nuts.





14. Tighten the 2 new RH catalytic converter-to-exhaust manifold or turbocharger nuts in the following sequence.
1. Tighten the RH lower catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).

2. Tighten the RH upper catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).






15. Tighten the LH isolator cap bolt.
- Tighten to 55 Nm (41 lb-ft).






16. Tighten the RH catalytic converter-to-LH catalytic converter Torca(R) clamp.
- Tighten to 55 Nm (41 lb-ft).






17. Tighten the 2 new LH catalytic converter-to-exhaust manifold or turbocharger nuts in the following sequence.
1. Snug the LH inner catalytic converter-to-exhaust manifold or turbocharger nut.

2. Tighten the LH outer catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).

3. Tighten the LH inner catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).






18. NOTICE: If equipped, do not excessively bend, twist or allow the exhaust to hang from the flexible pipe or damage to the muffler and tailpipe may occur.
Tighten the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolts in the following sequence.
1. Snug the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.

2. Tighten the inner exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm (46 lb-ft).

3. Tighten the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm (46 lb-ft).


19. Connect the 2 CMS (Catalyst Monitor Sensor) electrical connectors.

3.7L, 5.0L and 6.2L

20. Connect the 2 HO2S (Heated Oxygen Sensor) pushpins and electrical connectors.

3.5L GTDI (Gasoline Turbocharged Direct Injection)

21. Connect the RH HO2S (Heated Oxygen Sensor) pushpin and electrical connector.

All vehicles

22. If equipped, install the splash shield and the 4 fasteners.





3.5L GTDI (Gasoline Turbocharged Direct Injection)

23. Connect the LH HO2S (Heated Oxygen Sensor) pushpin and electrical connector.

All vehicles

24. Start engine and check for exhaust leaks.
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