Exhaust Pipe: Service and Repair

Exhaust Pipe Replacement

Tools Required
- SA9168NE Exhaust and Tailpipe Cutter

Removal Procedure

Notice: Do not over-flex or damage the flex joint when moving the flex joint from the normal mounting position.

Important: A service exhaust muffler will be needed when replacing the exhaust extension pipe on an originally equipped, welded system.

1. Raise and support the vehicle.
2. Support the exhaust muffler.






3. Cut the exhaust extension pipe just forward of the weld at the front of the exhaust muffler using the SA9168NE.
4. Release the muffler insulator from the underbody hanger and remove the exhaust muffler.






5. Support the catalytic converter pipe.
6. Remove the catalytic converter pipe-to-exhaust extension pipe nuts.
7. Release the exhaust extension pipe insulators from the underbody hangers, and support the extension pipe.
8. Separate the extension pipe from the converter pipe and remove the extension pipe from the vehicle.
9. Clean the converter pipe flange surface of any remaining gasket material.

Installation Procedure






1. Install a NEW exhaust gasket to the service exhaust extension pipe. The gasket is designed to be retained to the flange by the flange studs.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the catalytic converter pipe-to-exhaust extension pipe nuts.

Tighten
Tighten the nuts to 30 Nm (22 lb ft).

3. Position the extension pipe to the vehicle.
4. Connect the extension pipe to the converter pipe, and support the extension pipe.
5. Install the exhaust extension pipe insulators to the underbody hangers.






6. Install the service muffler to the vehicle.






7. Slide the muffler inlet pipe over the extension pipe, then install the muffler insulator to the underbody hanger.
8. Install a service muffler clamp to the muffler inlet pipe. Position the clamp approximately 19 mm (� in), from the edge of the muffler inlet, with the clamp nuts oriented away from the evaporative emission (EVAP) canister.
9. Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia.
10. While maintaining muffler positioning, tighten the exhaust clamp nuts.

Tighten
Tighten the nuts to 45 Nm (33 lb ft).

11. Lower the vehicle.