Installation

1. Install any studs that unscrewed from the head.

2. Position new manifold gaskets on both heads.

3. Position new front (left) catalyst/exhaust manifold in the vehicle.





4. Install new front (left) catalyst/exhaust manifold retaining nuts. Tighten the retaining nuts in sequence shown in Figure 2, to 18-22 N-m (13-16 lb/ft).

5. Connect the front (left) oxygen sensor and catalyst monitor electrical connectors.

6. Install the air deflector.

7. Position new rear (right) catalyst/exhaust manifold in the vehicle.

8. Install new catalyst/exhaust manifold nuts. Do not final torque retaining nuts at the time.

9. Lower the vehicle.

10. Connect the EGR tube to the EGR valve. Do not final torque retaining nut at this time.

11. Raise and support the vehicle.

12. Connect the EGR tube to the rear (right) catalyst/exhaust manifold.





13. Install new DPFE hoses. See Figure 3.

14. Tighten rear (right) catalyst/exhaust manifold retaining nuts in sequence shown in Figure 2, to 18-22 N-m (13-16 lb/ft).

15. Install oxygen sensor into rear (right) catalyst/exhaust manifold. Tighten sensor to 35-46 N-m (26-34 lb/ft).

16. Route oxygen sensor wiring to the oxygen sensor. Do not connect wiring.

17. Position alternator back into position, then install retaining bolts.

18. Install alternator rear bracket. Tighten retaining bolt to 20-30 N-m (15-22 lb/ft).

19. Install serpentine drive belt on alternator pulley.

20. Connect alternator electrical wiring.

21. Position right driveshaft bearing support bracket, then install retaining bolts. Tighten to 21-32 N-m (15-23 lb/ft).

22. Install right driveshaft bearing support shield, then install retaining nuts.

23. Install right wheelwell splash shield.

24. Position Y-pipe on mounting bracket and both catalyst/exhaust manifolds.

25. Install Y-pipe on mounting bracket retaining nut. Do not final torque retaining nut at this time.

26. Install Y-pipe-to-both catalyst/exhaust manifold flange retaining nuts. Tighten nuts to 34-36 N-m (26-33 lb/ft).

27. Tighten Y-pipe mounting bracket retaining nut to 30-40 N-m (22-30 lb/ft).

28. On models equipped with automatic transaxle, install flex-pipe hanger to underbody.

29. On models equipped with automatic transaxle, Install new gaskets on muffler inlet and flex-pipe inlet.

30. On models equipped with manual transaxle, install new gaskets on both ends of three-way catalyst.

31. Position three-way catalytic converter on muffler inlet and flex-pipe (automatic transaxle) or Y-pipe (manual transaxle).

32. Install three-way catalytic converter to flex-pipe or Y-pipe retaining nuts. Tighten nuts to 30-40 N-m (22-30 lb/ft).

33. Install three-way catalytic converter to muffler inlet retaining nuts. Tighten nuts to 34-46 N-m (26-33 lb/ft).

34. Connect rear catalyst monitor electrical connector, if equipped.

35. Lower vehicle.

36. From engine compartment, perform the following:

^ Connect right (rear) oxygen sensor electrical connector.

^ Tighten EGR tube to EGR valve to 35-45 N-m (26-33 lb/ft).

^ Connect idle air control vacuum hose.

^ Connect idle air control electrical connector.

37. Connect battery negative cable.

38. Remove memory saver.

39. Start vehicle and check and check for exhaust leaks.