Exhaust System Replacement

REMOVAL PROCEDURE





1. Disconnect the negative battery cable.
2. Raise the vehicle and support.
3. Remove the stabilizer bar bolts and straps from the rear crossmember. Position the stabilizer bar downward.





4. Remove the intermediate exhaust pipe-to-rear pipe bolts.





5. Remove the LH muffler from the muffler hanger.
6. Remove the LH muffler from the vehicle.
7. Remove the RH muffler from the muffler hanger.
8. Remove the RH muffler from the vehicle.





9. Disconnect the rear HO2S connectors.





10. Remove the takedown pipe-to-manifold flange nuts.





11. Remove the front exhaust hanger bolts from the takedown pipe bracket.





12. Remove the rear exhaust hanger bolts from the rear intermediate exhaust Dices.





13. Remove the intermediate pipe assembly from the vehicle.
14. Remove the rear H02S from the intermediate pipe.

INSTALLATION PROCEDURE





1. Coat the threads of the heated oxygen sensor with anti-freeze compound P/N 5613695, or equivalent if necessary.
2. Install the rear H02S to the intermediate pipe.
^ Tighten the rear H02S to 41 Nm (30 ft. lbs.).

3. Install the intermediate pipe assembly to the vehicle.
4. Hand start the following exhaust system bolts:
^ The rear exhaust hanger bolts
^ The takedown pipe flange nuts
^ The intermediate exhaust pipe to the rear intermediate exhaust pipe bolts
^ The takedown pipe hanger bolts






5. Install the RH muffler to the vehicle.
6. Install the RH muffler to the muffler hanger.
7. Install the LH muffler to the vehicle.
8. Install the LH muffler to the muffler hanger.





9. Reposition the stabilizer bar to the rear crossmember.

10. Install the stabilizer bar straps and bolts.
^ Tighten the rear stabilizer bar bolts to 50 Nm (37ft. lbs.)

11. Inspect the alignment of the exhaust system.
12. Tighten the exhaust system bolts starting at the rear and ending with the front exhaust hanger.
12.1. Tighten the intermediate exhaust pipe to rear exhaust pipe bolts to 50 Nm (37 ft. lbs.).
12.2. Tighten the rear exhaust hanger bolts to 50 Nm (37 ft. lbs.).
12.3. Tighten the exhaust manifold-to-takedown pipe nuts to 20 Nm (15 ft. lbs.).
12.4. Tighten the takedown pipe hanger bolts to 50 Nm (37 ft. lbs.).






13. Connect the rear H02S connectors.
14. Lower the vehicle.
15. Connect the negative battery cable.
^ Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.).

16. Program the Transmitters.