Removal Procedure
Servicing of the mufflers, resonator or pipe requires the replacement
of the exhaust system as a complete 1-piece unit.
Caution: In order to avoid being burned, do not service the exhaust system while
it is still hot. Service the system when it is cool.
Caution: Always wear protective goggles and gloves when removing exhaust parts
as falling rust and sharp edges from worn exhaust components could result
in serious personal injury.
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the oxygen sensor wiring harness heat shield. Refer to
Oxygen Sensor Wiring Harness Heat Shield Replacement
.
- Disconnect the heated oxygen sensor at the pigtail.
- Remove the heated oxygen sensor if replacement is necessary. Refer to
Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
in Engine Controls-4.6L.
- Remove the 4 nuts securing the catalytic
converter to the rear exhaust manifold pipe.
- Remove the catalytic converter gasket. Do not reuse the gasket.
- Suitably support the exhaust system.
- Remove the 2 bolts securing the center exhaust hangers to the rear suspension
support brackets.
- Remove the 2 bolts securing the rear exhaust hanger brackets to the rear compartment
rails.
- With the aid of an assistant, lower the exhaust system.
- Remove
the 2 nuts securing the rear exhaust hangers to the rear exhaust hanger brackets.
- Remove the rear exhaust hanger brackets from the rear exhaust hangers.
Installation Procedure
- Install
the rear exhaust hanger brackets to the rear exhaust hangers.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the 2 nuts securing the rear exhaust hangers to the rear exhaust hanger
brackets.
Tighten
Tighten the rear exhaust hanger nuts to 30 N·m (22 lb ft).
Notice: When inspecting or replacing exhaust system components, make sure there
is adequate clearance from all points on the underbody to prevent overheating
of the floor pan and possible damage to the passenger compartment insulation
and trim materials.
- Place a NEW catalytic converter gasket over the catalytic converter studs.
Notice: Do not over-flex or damage the flex joint when moving the flex joint from the normal mounting position.
- With the aid of an assistant, raise the exhaust system into position, aligning
the catalytic converter with the rear exhaust manifold pipe.
- Finger tighten the 4 nuts to the catalytic converter studs.
- Install the 2 bolts securing the rear exhaust hanger brackets to the rear compartment
rails.
Tighten
Tighten the rear exhaust hanger bolts to 50 N·m (37 lb ft).
- Install the 2 bolts securing the center exhaust hangers to the rear suspension
support brackets.
Tighten
Tighten the center exhaust hanger bolts to 30 N·m (22 lb ft).
- Tighten the 4 catalytic converter nuts previously installed in step 5.
Tighten
Tighten the catalytic converter nuts to 25 N·m (18 lb ft).
- Install the heated oxygen sensor. Refer to
Heated Oxygen Sensor Replacement - Bank 1 Sensor 2
in Engine Controls-4.6L.
- Remove the oxygen sensor wiring harness heat shield. Refer to
Oxygen Sensor Wiring Harness Heat Shield Replacement
.
- Lower the vehicle.