Muffler: Service and Repair

MUFFLER PIPE ASSEMBLY
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 OPERATION TIME.

1. Raise vehicle on hoist and apply penetrating oil to band clamp of component being removed (Fig. 1).
2. Remove ground strap from muffler.
3. Loosen band clamp for muffler/pipe assembly.

CAUTION: Do not use any tools to remove the rubber isolators-remove by hand only. Soapy water or silicone-based lubricant spray may be used to assist removal/installation of isolators. DO NOT use a petroleum-based lubricant on the isolators, as damage to the rubber material can occur.

4. Remove support isolators from muffler supports (Fig. 2).
5. Remove muffler/pipe assembly from resonator pipe.

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

NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used for the following reasons:
^ To insure 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

NOTE: Always work from the front to rear of exhaust system when aligning and tightening exhaust system components.

1. Loosely install muffler/pipe assembly onto resonator pipe.
2. Install support isolators to muffler supports.
3. Align muffler/pipe assembly to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them. Tighten band clamp to 54 Nm (40 ft. lbs.).
4. Connect ground strap to muffler.
5. Lower vehicle.
6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.