Muffler: Service and Repair

REMOVAL

Slip Joint Connection-Typical:

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

Exhaust Pipe And Muffler Support Insulators-Typical:

2. Loosen band clamp and remove support insulators at muffler. Remove muffler from exhaust pipe.

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.

3. Disconnect downstream heated oxygen sensor from the catalytic converter pipe.

Catalytic Converter To Exhaust Pipe Connection:

4. Remove clamp at the catalytic converter to exhaust pipe slip joint. Separate at slip joint.
5. When removing exhaust pipe, raise rear of vehicle to relieve body weight from rear suspension to provide clearance between pipe and lateral arms.

Catalytic Converter To Exhaust Manifold Connection-Federal:

6. Remove catalytic converter to exhaust manifold attaching fasteners.
7. Remove catalytic converter from vehicle. Remove and discard flange gasket (LEV only).
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: 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.

Catalytic Converter To Exhaust Manifold Connection-LEV:

1. Assemble catalytic convertor to exhaust manifold connection. Use a new flange gasket (LEV only) or image.
2. Assemble exhaust pipe to catalytic convertor and the support to the underbody
3. Install the muffler to exhaust pipe and the supports to the underbody.
4. Working from the front of system;
5. Align and tighten the catalytic convertor to exhaust manifold ball joint bolts to 27 Nm (20 ft. lbs.) or flex joint attaching nuts (LEV) to 28 Nm (250 inch lbs.).

Exhaust Clearance:

Band Clamp (Torca):

6. Align each component to maintain position and proper clearance with underbody parts and tighten band clamps to specifications.

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

7. Connect the downstream heated oxygen sensor and lower the vehicle.