Exhaust Seal Replacement Manifold Pipe Gasket - 3.5L

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.




Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

Important: Use caution handling the pipe that contains an oxygen sensor. Do not cut the wire. For removal or repositioning disconnect the electrical connector.

2. Remove the right (rear) exhaust manifold nuts from the three-way catalytic converter pipe.
3. Suitably support the exhaust system.
4. In order to remove the exhaust seal disconnect any hangers necessary to reposition the exhaust system.
5. Reposition the exhaust system.
6. Remove the exhaust seal.
7. Inspect all of the components for the following damage. Replace the components as necessary:

•

Cracks

•

Bends

•	Stripped threads

•	Corrosion damage

•

Leaks

1. Install the exhaust seal.
2. Install the exhaust system.
3. Connect any hangers.
4. Remove the exhaust system support.

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.

5. Install the right (rear) exhaust manifold nuts to the three-way catalytic converter pipe.

Tighten
Tighten the right (rear) exhaust manifold nuts to 65 N·m (48 lb ft).

6. Lower the vehicle.
7. Inspect the system for leaks.

Exhaust Seal Replacement Catalytic Converter

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.




Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

Important: Exercise caution handling the pipe that contains an oxygen sensor. Do not cut the wire. For removal or repositioning disconnect the connector.

2. Support the exhaust pipe and the three-way catalytic converter pipe.
3. In order to remove the three-way catalytic converter seal disconnect any hangers necessary to reposition the exhaust system.
4. Remove the catalytic converter bolts from the three-way catalytic converter pipe flange.
5. Reposition the exhaust system.
6. Remove the three-way catalytic converter seal.
7. Inspect all of the components for the following damage. Replace the components as necessary:

•

Cracks

•

Bends

•	Stripped threads

•	Corrosion damage

•

Leaks

1. Install the three-way catalytic converter seal.
2. Install the exhaust system.
3. Connect any 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.

4. Install the catalytic converter bolts through the three-way catalytic converter pipe flange.

Tighten
Tighten the catalytic converter bolts to 45 N·m (33 lb ft).

5. Remove the exhaust system support.
6. Lower the vehicle.
7. Inspect the system for leaks.

Exhaust Seal Replacement Manifold Pipe Gasket - 3800

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

2. In order to remove the exhaust manifold pipe gasket disconnect any hangers necessary to reposition the exhaust system.
3. Suitably support the exhaust system where hangers are removed.



4. Remove the right (rear) exhaust manifold pipe nuts from the exhaust manifold pipe studs.

Important: Exercise caution handling the pipe that contains an oxygen sensor. Do not cut the wire. For removal or repositioning disconnect the connector.

5. Reposition the exhaust system.
6. Remove the exhaust manifold pipe gasket.
7. Inspect all of the components for damage. Refer to Exhaust System Inspection .

1. Install the exhaust manifold pipe gasket.
2. Install the exhaust system.
3. Connect any hangers.
4. Remove the exhaust system support.

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.

5. Install the right (rear) exhaust manifold pipe nuts to the exhaust manifold pipe studs.

Tighten
Tighten the right (rear) exhaust manifold pipe nuts to 35 N·m (26 lb ft).

6. Lower the vehicle.
7. Inspect the exhaust system for leaks and underbody contact.