Exhaust Pipe: Service and Repair

Fig. 1 Exhaust System:

Fig. 5 Band Clamp:

REMOVAL -- EXHAUST PIPE AND MUFFLERS
1. Raise vehicle on hoist and apply penetrating oil to clamp nuts of component being removed.

Fig. 6 Exhaust Systems Components:

2. Remove clamp and supports at muffler to resonator assembly. Remove muffler from resonator pipe.
3. Remove clamp and supports at the resonator pipe to catalytic converter slip joint. Separate at slip joint and remove the resonator assembly.
4. Disconnect downstream heated oxygen sensor from the catalytic converter pipe if equipped.

Fig. 7 Ball And Flex Joint Connections:

5. Remove catalytic converter to exhaust manifold attaching fasteners. Remove catalytic converter from vehicle.
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.

When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used;
- 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.

Fig. 8 Exhaust System Support Insulators--Typical:

INSTALLATION -- EXHAUST PIPE AND MUFFLERS
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 and attach to the supports on the underbody.
3. Install the muffler to resonator pipe and attach to the supports on the underbody.
4. Working from the front of system;
a. Align and tighten the catalytic convertor to exhaust manifold fasteners.
b. 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 lb).
5. Connect the downstream heated oxygen sensor, if equipped.