I30 1996-1997

Exhaust System

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Catalytic Converter



Removal & Installation

CAUTION
In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.


CAUTION
Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

Follow these guidelines when working on the exhaust system:



Always replace exhaust gaskets with new ones when reassembling
 
With the engine running, check all tube connections for exhaust gas leaks, and the entire system for unusual noises
 
Check to ensure that the mounting brackets and mounting insulators are installed properly and are free from undue stress. Improper installation could result in excessive noise or vibration
 
Discard any Heated Oxygen Sensor (HO2S) which has been dropped from a height of more than 20 inches (0.5mm) onto a hard surface such as a concrete floor. Replace with a new HO2S.
 
Before installing a new HO2S, clean the exhaust system threads using an oxygen sensor thread cleaner tool, J-43897-18 or J-43897-12, and apply anti-seize lubricant.
 
Do not over-torque the HO2S. Doing so may cause damage to the HO2S, resulting in a Diagnostic Trouble Code (DTC) being set.
 

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect each joint and mounting, as necessary, using the appropriate power tools.
  4.  
  5. Remove the catalytic converter(s) from the vehicle.
  6.  

To install:


NOTE
Be sure to use genuine exhaust system parts, or equivalents, which are specially designed for heat resistance, corrosion resistance, and shape.

  1. Install in the reverse order of removal.
  2.  
  3. Remove deposits from the sealing surface of each connection. Connect them securely to avoid exhaust gas leakage.
  4.  
  5. When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/ left directions.
  6.  
  7. Temporarily tighten the mounting nuts. Check each exhaust component for unusual interference, and then tighten them to the specified torque as illustrated.
    NOTE
    Check exhaust pipes, muffler, and mounting for improper attachment, leaks, cracks, damage, or deterioration.

  8.  
  9. When installing the insulator, avoid large gaps or interference between the insulator and each exhaust pipe.
  10.  
  11. With the engine running, check the exhaust tube joints for exhaust gas leakage and unusual noises.
  12.  
  13. Check to ensure that mounting brackets and mounting insulators are installed properly and free from undue stress. Improper installation could result in excessive noise and vibration.

    Click image to see an enlarged view

    Fig. Exploded view of exhaust system with torque values (except California emission)-3.0L engine



    Click image to see an enlarged view

    Fig. Exploded view of exhaust system with torque values (California emission)-3.0L engine

  14.  

 
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