Emission Control Systems: Service and Repair

CATALYTIC CONVERTER

REMOVAL

REMOVAL - FRONT EXHAUST PIPES

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.





1. Raise and support the vehicle.
2. Disconnect the oxygen sensor harness connectors (6 and 7).
3. Support the exhaust system.
4. Remove the bolts at the left and right side exhaust manifold flanges (8 and 9).
5. Remove the center exhaust flange bolts (3).
6. Remove the left and right side exhaust pipes from the vehicle (5 and 10).





7. Remove the bolts (1) at the right side exhaust pipe flange.

REMOVAL - FRONT EXHAUST PIPES - SRT





WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.





1. Raise and support the vehicle.
2. Disconnect the oxygen sensor harness connectors (1).
3. Support the exhaust system.





4. Remove the bolts (1) at the left and right side exhaust manifold flanges.
5. Remove the left and right side center exhaust flange bolts.





6. Remove the left and right side exhaust pipe bolts (1) then remove the exhaust pipes from the vehicle.

INSTALLATION

INSTALLATION - FRONT EXHAUST PIPES





NOTE: Inspect the exhaust manifold flange surface. Replace as required.

1. Install bolts at right side exhaust pipe flange (11). Tighten to 20 Nm (15 ft. lbs.).
2. Position and support the front exhaust pipes in the vehicle.
3. Install bolts at the left and right exhaust manifold (8 and 9) flanges.
4. Install bolts at the center exhaust manifold flange (3).
5. Tighten exhaust manifold flange bolts to 20 Nm (15 ft. lbs.).
6. Tighten bolts at the center exhaust pipe flange to 20 Nm (15 ft. lbs.).
7. Connect oxygen sensor wiring harness connectors (6 and 7).
8. Route oxygen sensor wire harness in harness retainer.
9. Remove exhaust system support.
10. Lower the vehicle.

INSTALLATION - FRONT EXHAUST PIPES - SRT





NOTE: Inspect the exhaust manifold flange surface. Replace as required.





1. Position and support the front exhaust pipes in the vehicle.
2. Install bolts at the left and right exhaust manifold flanges.
3. Install bolts at the left and right center exhaust manifold flange.
4. Tighten exhaust manifold flange bolts to 20 Nm (15 ft. lbs.).
5. Tighten bolts at the left and right center exhaust pipe flange to 20 Nm (15 ft. lbs.).





6. Connect oxygen sensor wiring harness connectors (1).
7. Route oxygen sensor wire harness in harness retainer.
8. Remove exhaust system support.
9. Lower the vehicle.