Muffler: Service and Repair

EXHAUST PIPE AND MUFFLER

REMOVAL

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATING TIME.

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

NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water.

2. Remove exhaust system ground strap.






3. Loosen band clamp and remove support isolators at muffler. Remove muffler from exhaust pipe.
4. Loosen band clamp at the catalytic converter to intermediate pipe joint.
5. Remove intermediate pipe support isolator. Separate at slip joint and remove intermediate pipe.
6. Clean ends of pipes and muffler to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts.

NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent).

INSTALLATION
When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked.
1. Assemble intermediate pipe to catalytic converter and the isolator support to the underbody.
2. Install the muffler to intermediate pipe and the isolator supports to the underbody.












3. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. Tighten band clamps to 47 Nm (35 ft. lbs.).

CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp band has been stretched and has lost its clamping force and must be replaced.

*To replace the band clamp; remove the nut and and peel back the ends of the clamp until spot weld breaks.

NOTE: Maintain proper clamp orientation when replacing with new clamp.

4. Connect the exhaust system ground strap.