Exhaust Pipe: Service and Repair

Exhaust Extension Pipe Replacement (RPOs LE5/LSJ)
^ Tools Required
- SA9168NE Exhaust and Tailpipe Cutter

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 muffler pipe on an factory equipped system.





1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Support the exhaust muffler.
3. Cut the exhaust muffler pipe just forward of the weld at the front of the exhaust muffler using the SA9168NE.
4. Remove the muffler insulator from the underbody hanger and remove the exhaust muffler.
5. Deburr the muffler inlet pipe end as necessary.





6. Place a suitable jack stand under the catalytic converter for support.
7. If equipped with regular production option (RPO) LE5, remove the catalytic converter to muffler pipe nuts.





8. If equipped with RPO LSJ, remove the catalytic converter to muffler pipe nuts.





9. With the aid of an assistant, separate the exhaust muffler pipe insulators from the underbody hangers.
10. Remove the muffler pipe from the catalytic converter and remove the muffler pipe from the vehicle.
11. Remove and discard the muffler pipe gasket.
12. Clean the catalytic converter flange mating surfaces of any remaining gasket material.

Installation Procedure





1. Install a NEW gasket to the service muffler pipe studs.
2. With the aid of an assistant, install the muffler pipe to the catalytic converter and support the muffler pipe.
3. Install the muffler pipe insulators to the underbody hangers.





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

If equipped with RPO LSJ, install the catalytic converter to muffler pipe nuts.
^ Tighten the nuts to 30 Nm (22 ft. lbs.).





5. If equipped with RPO LE5, install the catalytic converter to muffler pipe nuts.
^ Tighten the nuts to 30 Nm (22 ft. lbs.).
6. Remove the jack stand from under the catalytic converter.





7. Slide the muffler inlet pipe over the muffler pipe, then install the muffler insulator to the underbody hanger.





8. Install a service muffler clamp to the muffler inlet pipe. Position the clamp approximately 19 mm (3/4 inch), from the edge of the muffler inlet, with the clamp nuts oriented away from the evaporative emission (EVAP) canister.
9. Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia.
10. While maintaining muffler positioning, tighten the exhaust clamp nuts.
^ Tighten the nuts to 45 Nm (33 ft. lbs.).
11. Lower the vehicle.