Exhaust Pipe: Service and Repair

Intermediate Pipe Replacement

Removal Procedure

Notice: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.

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

1. Raise and support the vehicle. Refer to Vehicle Lifting.
2. Support the exhaust muffler.





3. Cut the exhaust extension pipe just forward of the weld at the front of the exhaust muffler.
4. Release the muffler from the underbody hanger insulators and remove the exhaust muffler.





5. Support the catalytic converter pipe.
6. Remove the catalytic converter pipe-to-exhaust extension pipe nuts.
7. Release the exhaust extension pipe from the underbody hanger insulators, and support the extension pipe.
8. Separate the extension pipe from the converter pipe and remove the extension pipe from the vehicle.
9. Clean the converter pipe flange surface of any remaining gasket material.

Installation Procedure





1. Install a NEW exhaust gasket to the service exhaust extension pipe. The gasket is designed to be retained to the flange by the flange studs.Connect the extension pipe to the converter pipe, and support the extension pipe.

2. Notice: Refer to Fastener Notice in Service Precautions.

Install the catalytic converter pipe-to-exhaust extension pipe nuts.
^ Tighten the nuts to 30 Nm (22 ft. lbs.).





3. Install the exhaust extension pipe to the underbody hangers insulators.
4. Install the muffler to the vehicle.
5. Slide the muffler inlet pipe over the extension pipe, then install the muffler insulator to the underbody hanger.
6. Install a muffler clamp to the muffler inlet pipe. Position the clamp approximately 19 mm (� inch) from the edge of the muffler inlet, with the clamp nuts oriented away from the evaporative emission (EVAP) canister.
7. Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia.
8. While maintaining muffler positioning, tighten the exhaust clamp nuts.
^ Tighten the nuts to 45 Nm (33 ft. lbs.).
9. Lower the vehicle.