Catalytic Converter Replacement Bank 1

Tools Required

J 39194-B Heated Oxygen Sensor Wrench

Important:  The rear exhaust pipe and catalytic converter are only serviced as an assembly; components are not serviced separately.

1. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement .




Important: The heated oxygen sensor (HO2S) 2 uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

2. Remove HO2S 2 using the J 39194-B .



3. Remove the 2 bolts and 1 exhaust pipe nut at the manifold.
4. Remove the nuts at the outlet of the catalytic converter to crossover pipe.
5. Inspect the exhaust pipe-to-exhaust manifold flange.

Exhaust Pipe to Manifold Flange Warpage:

•	Service Limit: 0.7 mm (0.028 in) max.

•	Standard: 0.7 mm (0.028 in) max.

1. Install a new gasket on the exhaust manifold studs.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the rear exhaust pipe-to-manifold nut and bolts.

Tighten
Tighten the exhaust pipe-to-manifold nut and bolts to 31 N·m (23 lb ft).

3. Install the catalytic converter outlet gasket and fasten the outlet to crossover pipe with the nuts.

Tighten
Tighten the catalytic convertor to crossover pipe nuts to 31 N·m (23 lb ft).




4. Install the HO2S 2 using the J 39194-B .

Tighten
Tighten the oxygen-sensor-to-exhaust manifold to 45 N·m (33 lb ft).

5. Lower the vehicle to the ground, start the engine, and check for exhaust leaks.

Catalytic Converter Replacement Bank 2

Tools Required

J 39194-B Heated Oxygen Sensor Wrench

Important:  The front exhaust pipe and catalytic converter are only serviced as an assembly; components are not serviced separately.

1. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement .




Important: The heated oxygen sensor (HO2S) 2 uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

2. Remove HO2S 2 using the J 39194-B .



3. Remove the 3 exhaust pipe nuts at the manifold.
4. Remove the nuts at the outlet of the catalytic converter to crossover pipe.
5. Inspect the exhaust pipe-to-exhaust manifold flange.

Exhaust Pipe to Manifold Flange Warpage:

•	Service Limit: 0.7 mm (0.028 in) max.

•	Standard: 0.7 mm (0.028 in) max.

1. Install a new gasket on the exhaust manifold studs.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the front exhaust pipe-to-manifold nut and bolts.

Tighten
Tighten the exhaust pipe-to-manifold nut and bolts to 31 N·m (23 lb ft).

3. Install the catalytic converter outlet gasket and fasten the outlet to crossover pipe with the nuts.

Tighten
Tighten the catalytic convertor to crossover pipe nuts to 31 N·m (23 lb ft).




4. Install HO2S 2 using the J 39194-B .

Tighten
Tighten the oxygen-sensor-to-exhaust manifold to 45 N·m (33 lb ft).

5. Lower the vehicle to the ground, start the engine, and check for exhaust leaks.