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Catalytic Converter: Installation

NOTE: When assembling exhaust system DO NOT  tighten clamps until all components are aligned and clearances are checked.
  1. Assemble catalytic converter to exhaust manifold connection. Use a new flange gasket.
  2. Tighten the catalytic converter to exhaust manifold fasteners to 28 N.m (250 INCH lbs). See Figure .
  3. Install intermediate pipe and muffler. See MUFFLER  and INTERMEDIATE PIPE  .
  4. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. See Figure . For clearance specifications, see SPECIFICATIONS  .
    5. 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.
  5. Tighten band clamps to 47 N.m (35 ft. lbs).
  6. If removed, install downstream oxygen sensor. See Figure .
  7. Connect downstream oxygen sensor electrical connector.
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