Exhaust System & Turbocharger: Converter-Catalytic: Installation

NOTE: When assembling exhaust system do not tighten clamps until all components are aligned and clearances are checked.

Fig 1: Exhaust System To Manifold Connection

Courtesy of DAIMLERCHRYSLER CORP.

1 - GASKET

2 - CATALYTIC CONVERTER

3 - NUT

1. Assemble catalytic converter (2) to exhaust manifold connection. Use a new flange gasket (1).
2. Tighten the catalytic converter (2) to exhaust manifold fasteners to 28 N.m (250 in. lbs.).
3. Install intermediate pipe and muffler (Refer to EXHAUST SYSTEM/INTERMEDIATE PIPE - INSTALLATION) .
4. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. For clearance specifications (Refer to EXHAUST SYSTEM - SPECIFICATIONS) .
5. Tighten band clamps to 47 N.m (35 ft. lbs.).
   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.
   Fig 2: Locating Oxygen Sensor (1/1 Upstream & 1/2 Downstream)

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - DOWN STREAM O2 SENSOR

   2 - UP STREAM O2 SENSOR

6. If removed, install downstream oxygen sensor (1).
7. Connect downstream oxygen sensor (1) electrical connector.
8. 1.6L Engine - Connect upstream oxygen sensor (2) connector.
9. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
10. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.