Catalytic Converter: Service and Repair

Dual Converter Y-Pipe





Special Tool(s)





Material

Removal





1. Remove the engine roll restrictor bolts and the engine roll restrictor.





2. Remove the ground strap bolt, the ground strap and the heat shield nut.
3. With the vehicle in NEUTRAL, position it on a hoist.





4. Remove the splash shield and the air deflector.





5. Disconnect the Catalyst Monitor Sensor (CMS) electrical connectors.





6. Remove the heat shield nut, then position the heat shield out of the way.





7. Remove the engine mount nut.





8. Remove the transmission mount nut.





9. NOTE: Support the exhaust with mechanic's wire.

Remove the nuts and separate the three-way catalytic converter from the dual converter Y-pipe. Discard the nuts and the gasket.
10. Lower the vehicle.





11. Remove and discard the front dual converter Y-pipe-to-exhaust manifold nuts.





12. Remove and discard the rear dual converter Y-pipe-to-exhaust manifold bolt.





13. Using the special tools, raise the front of the engine.
14. Raise the vehicle.





15. Remove and discard the rear dual converter Y-pipe-to-exhaust manifold bolt.





16. CAUTION: The sharp edges on the converter can cut the CV joint boot. Make sure to protect the half-shaft boot with a suitable covering before removing the converter assembly.

CAUTION: Use caution removing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.

Remove the dual Y-pipe converter assembly.





17. Remove the gaskets and, if necessary, the CMS.
^ Discard the gaskets.

18. Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.

Installation





1. Install the new gaskets and, if removed, install the Catalyst Monitor Sensors (CMS).





2. NOTE: Using silicone lubricant, lubricate the studs on the front of the dual converter Y-pipe and in the tapped holes on the rear of the dual converter Y-pipe.

Position the dual converter Y-pipe and loosely start the front nuts and the rear bolt.





3. Tighten the new rear dual converter Y-pipe-to-exhaust manifold bolt.
4. Lower the vehicle.





5. NOTE: To correctly seat the converter, alternately tighten the exhaust manifold-to-catalytic converter nuts to specification.

Tighten the new front dual converter Y-pipe-to-exhaust manifold nuts.
6. Lower the engine and remove the special tools.





7. Tighten the new rear dual converter Y-pipe-to-exhaust manifold bolt.





8. Install the engine roll restrictor and tighten the bolts.





9. Position the heat shield into place. Install the ground strap and tighten the ground strap bolt and heat shield nut.
10. Raise the vehicle.





11. Tighten the heat shield nut.





12. Tighten the engine mount nut.





13. Tighten the transmission mount nut.





14. NOTE: Clean the mating surfaces of the three-way converter and the dual converter Y-pipe.

NOTE: To correctly seat the converters, alternately tighten the three-way converter-to-dual converter Y-pipe nuts to specification.

Connect the three-way converter to the dual converter Y-pipe. Using silicone lubricant, lubricate the studs on the three-way converter, then install and tighten the nuts.





15. Connect the CMS electrical connectors.





16. Install the splash shield and the air deflector, and tighten the screws.
17. Lower the vehicle.