Muffler and Tailpipe

Muffler and Tailpipe

Removal

NOTICE: Do not use oil or grease-based lubricants on the isolators. They may cause deterioration of the rubber.

NOTICE: Oil or grease-based lubricants on the isolators may cause the exhaust isolator to separate from the exhaust hanger bracket during vehicle operation.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2. Support the muffler assembly with a suitable jackstand.





All vehicles except Gasoline Turbocharged Direct Injection (GTDI)

3. Remove the Torca(R) clamp nut.

4. NOTICE: The resonator must be supported to prevent damage to the flexible pipe.

Using a length of mechanic's wire, support the resonator.

GTDI vehicles

5. Remove the 4 LH and RH exhaust flexible pipes-to-underbody catalytic converter nuts.
- Discard the nuts and gaskets.

All vehicles

6. NOTICE: Do not damage or tear the isolators during removal.

Using soapy water, separate the isolators and remove the muffler assembly from the vehicle.

Installation

All vehicles except GTDI

1. Grind the spot weld and the tac weld from the Torca(R) clamp and remove the clamp.

2. Clean the uneven surface area and position the new Torca(R) clamp.





All vehicles

3. NOTE: Inspect and replace any isolators found to be damaged or torn during the removal process.

Install the muffler assembly in the isolators and support with a suitable jackstand.





GTDI vehicles

4. Install the new LH and RH exhaust flexible pipe-to-underbody catalytic converter gaskets and nuts.
- Tighten to 40 Nm (30 lb-ft).

All vehicles except GTDI

5. NOTE: Make sure the clamp position is no more than 27.5 mm (1.08 in) or less than 25.5 mm (1 in) from the inlet of the pipe.

Make sure the back of the slot is covered by the clamp and the button is fully seated inside the notch.





6. Tighten the Torca(R) clamp.
- Tighten to 55 Nm (41 lb-ft).