Intermediate Pipe Replacement 2.2 L

Notice: Do not over-flex or damage the flex joint when moving the flex joint from the normal mounting position.

Important: A service muffler will be needed when replacing the intermediate pipe on an originally equipped, welded system.

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Support the three way catalytic converter.



3. Cut the intermediate pipe (1) at the muffler (2).



4. Remove the intermediate pipe bolts at catalytic converter..



5. Remove the intermediate pipe from the hanger.
6. Remove the intermediate pipe.



7. Remove the three way catalytic converter seals.
8. Clean the flange surface.

1. Install the three way catalytic converter seals.



2. Install the intermediate pipe to the hanger.




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 intermediate pipe bolts to catalytic converter.

Tighten
Tighten the intermediate pipe bolts to 30 N·m (22 lb ft).




4. Weld the muffler (2) to the intermediate pipe (1).
5. Lower the vehicle.

Intermediate Pipe Replacement 2.4 L

Notice: Do not over-flex or damage the flex joint when moving the flex joint from the normal mounting position.

Important: A service muffler will be needed when replacing the intermediate pipe on an originally equipped, welded system.

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Support the three way catalytic converter.



3. Cut the intermediate pipe (1) at the muffler (2).



4. Remove the intermediate pipe bolts.



5. Remove the intermediate pipe from the hanger.
6. Remove the intermediate pipe.



7. Remove the three way catalytic converter seal.
8. Clean the flange surface.

1. Install the three way catalytic converter seal.



2. Install the intermediate pipe to the hanger.




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 intermediate pipe bolts.

Tighten
Tighten the intermediate pipe bolts to 30 N·m (22 lb ft).




4. Weld the muffler (2) to the intermediate pipe (1).
5. Lower the vehicle.