Muffler: Service and Repair

REMOVAL

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER 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.

Figure 6:

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.

Figure 7:

2. Loosen band clamp and remove support insulators at muffler. Remove muffler from exhaust pipe.
3. Disconnect downstream heated oxygen sensor from the catalytic converter pipe.

Figure 8:

4. Loosen band 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.
6. 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.
1. Assemble exhaust pipe to catalytic converter and the isolator support to the underbody
2. Install the muffler to exhaust pipe and the isolator supports to the underbody.

Figure 9:

Figure 10:

3. Working from the front of system-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 tightened 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 clamping force and must be replaced.

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