Exhaust System: Service and Repair

REMOVAL - EXHAUST SYSTEM

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 OPERATION TIME.








It is easier to service the exhaust system module components or, when system is removed from the vehicle.
1. Raise vehicle on hoist.
2. Apply penetrating oil and loosen band clamps at resonator connector.
3. Separate exhaust module at front resonator from the converter down pipes.

CAUTION: At this time, the exhaust system is held by only isolators. Support the exhaust system underneath the front resonator and the muffler while the isolators are being removed. Do not use any tools to remove the isolators, remove by hand only. Soapy water or silicone-based spray may be used to assist removal. Do Not use a petroleum based lubricant on the isolators. This will damage the rubber material.

4. Support exhaust system with jack stand.
5. Remove screw attaching exhaust system ground strap.








6. Remove the rubber isolators from the rear suspension crossmember and support brackets on body and.
7. Lower exhaust system and lay on the ground.

NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts be used for the following reasons:

^ 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.

INSPECTION
Inspect the exhaust pipes, catalytic converters, muffler, and resonators for cracked joints, broken welds and corrosion damage that would result in a leaking exhaust system. Inspect the clamps, support brackets, and insulators for cracks and corrosion damage.

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

INSTALLATION - EXHAUST SYSTEM
1. Install and loose assemble the front resonator to the converter pipes.
2. Place the exhaust system on two supports (one on side of muffler, one behind the resonator). Connect the system to the converter pipes.
3. Install the system's rubber isolators onto the support brackets and.
4. Install exhaust system ground strap.
5. Visually inspect the isolators. They should be straight when viewing from front to back of the vehicle. Working from the front of system, align each component to maintain position and proper clearance with underbody parts.
6. Tighten band clamps to 61 Nm (45 ft. lbs.).
7. Lower the vehicle.