INSTALLATION
UNDER FLOOR CATALYTIC CONVERTER
When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked.
1. Install under floor catalytic converter and the isolator supports to the underbody .
2. Position spherical gasket (2) with white side facing rear of vehicle, install springs, and bolts (3). Tighten bolts to 33 N·m (24 ft. lbs.).
3. Install I-Pipe/muffler assembly (Refer to 11 - EXHAUST SYSTEM/MUFFLER - INSTALLATION)
4. Working from the front of system; align each component to maintain position and proper clearance with underbody parts.
5. Tighten band clamps to 55 N·m (40 ft. lbs.).
CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp band has been stretched and has lost its clamping force and must be replaced.
NOTE: Maintain proper clamp orientation when replacing with new clamp.
6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
CATALYTIC CONVERTER - FWD
1. Position catalytic converter into I-Pipe/muffler assembly.
2. Using new gasket position catalytic converter against exhaust manifold.
3. Install flange bolts. Tighten to 29 N·m (21 ft. lbs.).
4. Working from the front of system; align each component to maintain position and proper clearance with underbody parts.
5. Tighten band clamps to 55 N·m (40 ft. lbs.).
CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced.
6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
INSTALLATION - MANIVERTER
NOTE: When assembling exhaust system do not tighten clamps until all components are aligned and clearances are checked.
1. Position maniverter (1) in vehicle. Use a new flange gasket.
2. Using new gasket, install maniverter (1) and mounting bolts. Tighten bolts to 28 N·m (250 in. lbs.).
3. Install secondary thermostat (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - INSTALLATION).
4. Install under floor catalytic converter (Refer to 11 - EXHAUST SYSTEM/CATALYTIC CONVERTER - INSTALLATION).
5. Working from the front of system; align each component to maintain position and proper clearance with underbody parts.
6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
DIESEL ENGINE
1. Position catalytic converter (1) in vehicle.
2. Install gasket (3) and clamp (2). Hand tighten clamp (2).
3. Install catalytic converter mounting bolt (4).
4. Install intermediate pipe (Refer to 11 - EXHAUST SYSTEM/INTERMEDIATE PIPE - INSTALLATION).
5. Working from the front of system; align each component to maintain position and proper clearance with underbody parts.
6. Tighten clamp (2) to 7 N·m (61.5 in. lbs.).
7. Tighten catalytic converter mounting bolt (4) to 28 N·m (250 in. lbs.).