Exhaust System: Service and Repair

REMOVAL

Flex-Joint Connections:

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

Exhaust System Components:

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

Exhaust System Support Isolators - Typical:

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

Exhaust System:

5. Disconnect downstream heated oxygen sensor from the catalytic converter pipe.
6. Remove catalytic converter to exhaust manifold attaching fasteners. Remove catalytic converter from vehicle.
7. 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 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
When assembling exhaust system do not tighten clamps until components are aligned and supports have equal load on them.
1. Assemble catalytic convertor to exhaust manifold connection.
2. Assemble resonator pipe to catalytic convertor. Attach isolators to the supports on the underbody.
3. Install the muffler to resonator pipe. Attach isolators to the supports on the underbody.

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

4. Align and tighten the catalytic convertor to exhaust manifold fasteners. Torque fasteners to 32 Nm (24 ft. lbs.).

Band Clamp:

5. 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.).
6. Connect ground strap.
7. Connect the downstream heated oxygen sensor.