Removal and Installation

NOTE: This procedure addresses both left and right converter assemblies. Number references in text specify numbered components in image.

REMOVE
1. Position vehicle on hoist or jack up and place on stands.
2. Remove oxygen sensor harness from clips on right fender well. Unplug sensor connectors.
3. For improved access to manifold flange nuts, remove air filter cover and element.
4. Remove oxygen sensor harness from clips on left fender well. Unplug sensor connectors.
5. Unplug connector from air temperature sensor located in air filter cover intake pipe. Remove air filter cover and element.

Downpipe Flange Nuts:

6. From beneath vehicle, unscrew and remove right oxygen sensor (1).
7. Remove steering rack heat shield.
8. Remove 2 bolts holding support bracket between exhaust system and transmission bell housing.
9. Remove 3 nuts securing downpipe flange to exhaust manifold. Loosen 4th nut but leave it attached to support the system (2).

Rear Flange Nuts And Bolts:

10. Remove 2 nuts and bolts (3) from flange joint (1) between front converter section and rear silencer (muffler) section. Loosen 3rd nut and bolt.
11. If necessary, align steering rack lower U-joint to ease front pipe removal.
12. With an assistant supporting the system, remove nuts and bolts previously loosened but left in place.
13. Carefully separate assembly from exhaust manifold flange and rear flange joint. Lower assembly from vehicle.
14. Repeat steps 6 - 13 to remove left side converter assembly.

REFIT

Flange Sealing Rings:

1. Install sealing rings (1) on right downpipe flanges.
2. Apply exhaust sealant (TIVOLI KAY ADHESIVES No. 5696 or equivalent) sparingly to outer surface of rear sealing ring (4) and place ring in rear section joint.
3. With help from an assistant, position converter assembly in vehicle.
4. Screw one nut onto manifold flange (2) and one bolt, washer and lock nut to rear joint (3).
5. Install and partially tighten remaining nuts, bolts and washers to rear joint.
6. Install and partially tighten remaining nuts to manifold flange.
7. Check for adequate clearance around downpipe converter and tighten nuts to specified torque. Ensure that gap between pipe flanges is even.
8. Tighten nuts and bolts at rear joint flange to specified torque.
9. Install support bracket between exhaust system and bell housing.
10. Install oxygen sensor and route harness along inner fender.
11. Repeat steps 1 - 10 to install left side assembly. Ensure that installation allows adequate clearance for oil filter removal.
12. Under hood, connect oxygen sensor plugs and replace harnesses in retaining clips.
13. Replace air cleaner elements and covers. On left side, connect plug to air temperature sensor.

Downpipe To Manifold Flange
22 - 26 ft lb (30 - 35 Nm)

Rear Joint Flange
11 - 13 ft lb (15 - 18 Nm)

Oxygen Sensor
36 - 44 ft lb (50 - 60 Nm)