Exhaust System Removal and Installation

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 clamp nuts of component being removed.
2. Loosen clamp at muffler to resonator/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.

3. Remove support isolators from muffler supports.






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






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






8. Disconnect upstream heated oxygen sensor (2.5L engine).






9. Remove catalytic converter to exhaust manifold attaching fasteners. Remove catalytic converter from vehicle.
10. 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. Tighten fasteners to 28 Nm (250 inch lbs.).






5. Align each component to maintain position and proper clearance with underbody parts. Also, all supports should have equal load on them. Tighten clamps to 54 Nm (40 ft. lbs.).
6. Connect ground strap.
7. Connect the downstream heated oxygen sensor.
8. Connect the upstream heated oxygen sensor