Exhaust System: Service and Repair

REMOVAL - EXHAUST SYSTEM

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.

It is easier to service the exhaust system components (Fig. 1) when system is removed from the vehicle.
1. Raise vehicle on hoist.
2. Disconnect the two oxygen sensor connectors.
3. Remove the nuts at the exhaust manifold.

CAUTION: At this time, the exhaust system is held by only isolators. Support the exhaust system underneath the front resonator and the muffler while the isolators are being removed. Do not use any tools to remove the isolators, remove by hand only. Soapy water or silicone-based spray may be used to assist removal. Do Not use a petroleum based lubricant on the isolators. This will damage the rubber material.

4. Support exhaust system with jack stand.





5. Remove the rubber isolators from the support brackets (Fig. 2).
6. Lower exhaust system and lay on the ground.

NOTE: Care must be taken not to scratch the black paint on the rear of the muffler (Fig. 2).

NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts be used for the following reasons:

^ To ensure 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 - EXHAUST SYSTEM
1. Install and loose assemble the front resonator to the converter pipes.
2. Place the exhaust system on two supports (one on side of muffler, one behind the resonator). Connect the system to the exhaust manifold. Do not tighten the nuts.
3. Install the system's rubber isolators onto the support brackets (Fig. 2).
4. Visually inspect the isolators. They should be straight when viewing from front to back of the vehicle. Working from the front of system, align each component to maintain position and proper clearance with underbody parts.
5. Tighten the catalytic converter-to-exhaust manifold nuts to 37 Nm (325 inch lbs.) and torca clamp to 54 Nm (459 inch lbs.).
6. Lower the vehicle.
7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
8. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.