Exhaust Pipe: Service and Repair

REMOVAL
1. Raise vehicle on hoist and apply penetrating oil to clamp nuts of component being removed.





2. Remove clamp and supports at muffler to restore assembly. Remove muffler from resonator pipe.

Exhaust System Support Insulators-JX:

3. Remove ground strap.
4. Remove clamp and supports at the resonator pipe to catalytic convertor slip joint. Separate at slip joint and remove the resonator assembly.

Flex-Joint Connections:

5. Disconnect downstream heated oxygen sensor from the catalytic converter pipe.
6. Vehicle equipped with 2.5L engine disconnect upstream heated oxygen sensor.
7. Remove catalytic converter to exhaust manifold attaching fasteners. Remove catalytic converter from vehicle.
8. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts.

NOTE: Band clamps are spot welded to exhaust system. If a band clamp must be replaced, the spot weld must be ground to the exhaust pipe.

NOTE: When replacement is required on any component of the exhaust system, its most important that original equipment parts (or their equivalent) be used:

- To ensure proper alignment with other parts in the system.
- Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could affect emissions and performance.

INSTALLATION
When a seemingly exhaust system do not tighten clamps until components are aligned and supports have equal load on them.
1. Assemble catalytic converter to exhaust manifold connection.
2. Assemble resonator pipe to catalytic convertor and attach to the supports on the underbody.
3. Install the muffler to the resonator pipe and attach to the supports on the underbody.
4. Working from the front of system:
5. Align and tighten the catalytic converter to exhaust manifold fasteners. On 2.4L engine torque shoulder bolts to 28 Nm (250 inch lbs.). On 2.5L engine torque fasteners to 32 Nm (24 ft. lbs.).

Auxiliary Jumper Terminal:

6. Align each component to maintain position and proper clearance with underbody parts and that all supports have equal load on them. Tighten clamps to 80 Nm (60 ft. lbs.).
7. Connect ground strap.
8. Connect the downstream heated oxygen sensor.
9. Connect the upstream heated oxygen sensor, 2.5L engine.