Catalytic Converter Replacement Gasoline Below 8600 lb GVWR

1. Raise and suitably support the vehicle. Refer to General Information.



2. Disconnect the oxygen sensor electrical connections.



3. Remove the nuts and the flange gaskets from the Y-pipe and the exhaust manifold.



4. Remove the nuts and washers from the Y-pipe flat flange.
5. Remove the Y-pipe and the catalytic converter assembly.

1. Position the Y-pipe and the catalytic converter assembly to the flat flange.
2. Install the washers and the nuts to the flat flange studs.

Tighten
Tighten the nuts to 48 N·m (35 lb ft).

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.




3. Install the flange gaskets and the nuts to the exhaust manifold.

Tighten
Tighten the nuts to 65 N·m (48 lb ft).




4. Connect the oxygen sensor electrical connections.
5. Check for clearance and alignment.
6. Lower the vehicle.

Catalytic Converter Replacement Gasoline Above 8600 lb GVWR

1. Raise and suitably support the vehicle. Refer to General Information.



2. Disconnect the oxygen sensor electrical connections.



3. Remove the nuts and the flange gaskets from the Y-pipe and the exhaust manifold.



4. Remove the nuts and washers from the Y-pipe flat flange.
5. Remove the Y-pipe and the catalytic converter assembly.
6. Remove the muffler and the catalytic converter assembly.

1. Install the muffler and the catalytic converter assembly.



2. Position the Y-pipe and the catalytic converter assembly to the flat flange.
3. Install the washers and the nuts to the flat flange studs.

Tighten
Tighten the nuts to 48 N·m (35 lb ft).

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.




4. Install the flange gaskets and the nuts to the exhaust manifold.

Tighten
Tighten the nuts to 65 N·m (48 lb ft).




5. Connect the oxygen sensor electrical connections.
6. Check for clearance and alignment.
7. Lower the vehicle.

Catalytic Converter Replacement Diesel

1. Raise and suitably support the vehicle. Refer to General Information.



2. Remove the flange joint from the front of the catalytic converter assembly.



3. Remove the U-bolt from the rear of the catalytic converter assembly.
4. Remove the catalytic converter from the front exhaust pipe and the intermediate exhaust pipe.

1. Install the catalytic converter to the front exhaust pipe and the intermediate exhaust pipe.
2. Install new U-bolts and flange gasket at the front and rear of the catalytic converter.

Tighten
Tighten the nuts to 40 N·m (29 lb ft).

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.

3. Check for clearance and alignment.
4. Lower the vehicle.