Exhaust System: Service and Repair

NOTE: It is easier to service any portion of the exhaust system if the entire exhaust system (except the exhaust manifolds) is removed from the vehicle.

REMOVAL
1. Raise vehicle on swing arm hoist.





2. Apply penetrating oil and remove to the front down pipes to exhaust manifolds nuts.
3. Apply penetrating oil and remove the front down pipes to transmission intermediate support bracket bolts.

CAUTION: At this time, the exhaust system is held by only isolators. Support the exhaust system underneath the under floor convertor 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. Remove the rubber isolators from the welded exhaust system rod wire hangers.
5. Carefully maneuver the front down pipes past the engine, support cradle, and transmission. Lay the exhaust system on the ground.

NOTE: When replacement is required on any component of the exhaust system, it is most important that original equipment parts 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.

INSTALLATION
1. Install and loose assemble the front pipes to the exhaust manifolds and the transmission support bracket.
2. Place the exhaust module onto two supports (one under the under floor catalytic convertor, one under the muffler). Slide the module forward onto the front pipes until the front of the under floor convertor inlet bushings are touching the positive stop tabs on the front pipes.
3. Install the module's rubber isolators onto the body brackets.
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. Orientate and tighten all clamps and supports to the proper torques and clearances.
6. Lower the vehicle.