Catalytic Converter - Underbody Removal/Installation

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CATALYTIC CONVERTER UNDERBODY REMOVAL/INSTALLATION - HYBRID

Removal

CAUTION:Do not use oil or grease-based lubricants on the insulators. They may cause deterioration of the rubber.

CAUTION:Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation.
NOTE:The catalytic converter and muffler assembly is 1-piece construction. The service catalytic converter and muffler is a 2-piece construction. It is necessary to cut the production exhaust to enable the service section to be fitted. Before cutting any part of the exhaust system, check that the position of the cut is correct in comparison to the service section being installed.
1. With the vehicle in NEUTRAL, position it on a hoist. See Lifting.

2. Disconnect the catalyst monitor sensor electrical connector.

3. Remove and discard the 2 exhaust catalytic converter-to-intermediate pipe spring nuts.

4. Remove and discard the 2 resonator-to-muffler spring nuts.

5. Detach the 3 exhaust hangers and remove the catalytic converter and muffler assembly.

- Discard the gaskets.






6. Cut the exhaust system as indicated in illustration.

Installation

CAUTION:The exhaust hanger insulators are constructed of a special material. Use only the correct specification exhaust hanger insulator or damage to the exhaust system may occur.
NOTE:Check the exhaust hanger insulators for damage and fatigue. Install new exhaust hanger insulators as required.
NOTE:Thoroughly clean the sealing surfaces of the flanges using an abrasive pad.






1. Install the service clamp onto the catalytic converter section.

NOTE:Do not tighten the service clamp at this time.






2. Install the catalytic converter section and service clamp onto the muffler section.

3. Attach the catalytic converter and muffler assembly to the 3 exhaust hangers.

NOTE:Do not tighten the service clamp at this time.
4. Install a new gasket and 2 new resonator-to-muffler spring nuts.

- Tighten to 20 Nm {2.0 kgf-m, 177 in-lbf}.

5. Install a new gasket and 2 new catalytic converter-to-exhaust intermediate pipe spring nuts.

- To install, tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.

6. Tighten the 4 service clamp nuts to 47 Nm {4.7 kgf-m, 35 ft-lbf}.