Exhaust System: Service and Repair

Exhaust System

Service Repair No - 30.10.08

Special Service Tools:

Removal
1. Disconnect the battery ground cable.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

2. Raise and support the vehicle.
3. Disconnect the LH catalytic converter from the exhaust manifold.
^ Remove and discard the 2 nuts.
4. Disconnect the RH catalytic converter from the exhaust manifold.
^ Remove and discard the 2 nuts.





5. Disconnect the LH heated oxygen sensor (HO2S) electrical connector.
^ Repeat the above procedure for the RH side.





6. Disconnect the LH catalyst monitor sensor electrical connector.
^ Release the wiring harness.
^ Repeat the above procedure for the RH side.





7. Disconnect the 2 front exhaust hangers.





8. With assistance, remove the exhaust system.
^ Remove the 2 nuts.





NOTE: Do not disassemble further if the component is removed for access only.

9. Remove both rear exhaust hanger assemblies.





10. Using the special tool, remove the HO2S.
^ Repeat the above procedure for the remaining sensor.
11. Using the special tool, remove the catalyst monitor sensor.
^ Repeat the above procedure for the remaining sensor.





Installation

CAUTION: Make sure the anti-seize compound does not contact the catalyst monitor sensor tip.

1. Using the special tool, install the catalyst monitor sensor.
^ Clean the components.
^ Apply an anti-seize compound to the thread of the sensor.
^ Tighten the catalyst monitor sensor to 45 Nm (33 ft. lbs).
^ Repeat the above procedure for the remaining sensor.

CAUTION: Make sure the anti-seize compound does not contact the HO2S tip.

2. Using the special tool, install the HO2S.
^ Clean the components.
^ Apply an anti-seize compound to the thread of the sensor.
^ Tighten the HO2S to 45 Nm (33 ft. lbs).
^ Repeat the above procedure for the remaining sensor.
3. Install the rear exhaust hanger assemblies.
4. With assistance, install the exhaust system.
^ Attach the exhaust hangers.
^ Tighten the nuts to 45 Nm (33 ft. lbs).

CAUTION: Make sure the catalyst monitor sensor wiring harness is not twisted more than 180 degrees and is not in contact with either the exhaust or driveshaft.

5. Connect the catalyst monitor sensors.
^ Secure the wiring harness.

CAUTION: Make sure the HO2S wiring harness is not twisted more than 180 degrees and is not in contact with either the exhaust or driveshaft.

6. Connect the HO2S electrical connectors.
7. Position the RH catalytic converter to the exhaust manifold.
^ Clean the components.
^ Tighten the new nuts to 20 Nm (15 ft. lbs).
8. Position the LH catalytic converter to the exhaust manifold.
^ Clean the components.
^ Tighten the new nuts to 20 Nm (15 ft. lbs).
9. Connect the battery ground cable.