Front Exhaust Pipe to Three Way Catalytic Converter

WARNING: Make sure vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. Make sure hoist does not contact fuel or brake lines.

REMOVAL
1. Raise vehicle squarely on a lift.

CAUTION: Do not apply grease or silicon products to the rear heated oxygen sensor. Do not alter the wiring in any way. The wires carry air reference to the sensor.





2. Remove rear heated oxygen sensor wiring harness from cradle by pushing up on retaining clip tab.





3. Remove Connector Position Assurance (CPA) device and unplug rear heated oxygen sensor wiring harness from engine harness.





4. Remove rear heated oxygen sensor wiring harness from trough in converter heat shield by gently pulling wiring harness from its retaining clips.
5. Remove rear heated oxygen sensor. If necessary, use a liquid penetrate before removing sensor.

CAUTION: The rear heated oxygen sensor uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

6. Remove the front exhaust pipe fasteners at manifold and discard gasket.

Rear Oxygen Sensor:

7. Remove the front exhaust pipe fasteners at rear of three way catalytic converter. See Powertrain Management.

CAUTION: Do not bend the front exhaust pipe hanger attached to the engine stiffening bracket when servicing the front exhaust pipe and/or three way catalytic convertor. Bending the bracket may cause premature failure.

8. Remove the exhaust pipe support bracket to exhaust pipe fasteners and remove the pipe.





9. Remove three way catalytic converter gasket and discard.
10. Inspect the front exhaust pipe-to-exhaust manifold flange.

INSTALLATION
1. Install a new gasket on exhaust manifold studs.





2. Install front exhaust pipe-to-manifold fasteners. Torque to 31 Nm (23 ft. lbs.).

NOTE: Make sure the exhaust pipe bracket is positioned on the rearward side of the bracket bolted to the powertrain.

3. Install the two exhaust pipe support bracket-to-exhaust pipe bracket fasteners. Torque to 31 Nm (23 ft. lbs.).
4. Install front exhaust pipe to three way catalytic converter gasket and fasteners. Torque to 25 Nm (19 ft. lbs.).

CAUTION: Always use a nickel-based anti-seize compound on the threads of the oxygen sensor. If the oxygen sensor is replaced, do not apply anti-seize to the new sensor. New sensors have anti-seize pre-applied. Never use silicone products; silicone products will damage the oxygen sensor.

5. Install rear heated oxygen sensor. Torque to 45 Nm (33 ft. lbs.).

NOTE: Make sure to center marker tape with the edge of the trough. The marker tape must be centered with the edge of the trough to ensure enough slack in the harness.





6. Install rear heated oxygen sensor wiring harness into the retaining clips in the trough in the converter heat shield.
7. Plug rear heated oxygen sensor wiring harness into engine harness.
8. Install the CPA device in the electrical connector.
9. Install rear heated oxygen sensor wiring harness retaining clip into cradle.
10. Check the system for leaks.
11. Lower vehicle from hoist.