Tools Required

J 29800 Cut-Off Tool

1. Remove the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls.




Important: Ensure a minimum of 38 mm (1.5 inches) of the expanded portion of the intermediate pipe/resonator remains for installation.

2. Cut the intermediate pipe/resonator (1) at the converter weld using the J 29800 . Cut the pipe as close to the weld as possible.



3. Remove the hangers from the intermediate pipe/resonator.
4. Support the following:

•	The intermediate pipe/resonator

•	The catalytic converter




5. Separate the intermediate pipe/resonator from the catalytic converter.



6. If both pipes were cut through in step 2, remove the remainder of the catalytic converter pipe from the intermediate pipe/resonator.



7. Remove the 4 nuts securing the catalytic converter to the exhaust manifold pipe.
8. Remove the catalytic converter from the exhaust manifold pipe.
9. Remove the catalytic converter gasket. Do not reuse the gasket.

1. Place a NEW catalytic converter gasket over the catalytic converter studs.
2. Position the catalytic converter to the exhaust manifold pipe.

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 4 nuts securing the catalytic converter to the exhaust manifold pipe.

Tighten
Tighten the catalytic converter nuts to 25 N·m (18 lb ft).

4. Support the catalytic converter.



5. Slide the intermediate pipe/resonator over the catalytic converter outlet.
6. Align the system for proper clearances to the underbody. Refer to Exhaust System Alignment .
7. Install the U bolt type clamp.

Tighten
Tighten the U bolt clamp nuts to 40 N·m (30 lb ft).




8. Install the hangers to the intermediate pipe/resonator.
9. Remove the supports from the following:

•	The intermediate pipe/resonator

•	The catalytic converter

10. Install the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls.