Exhaust System: Service and Repair

COMPONENT REPLACEMENT
Exhaust system components may be assembled by means of welds or flanged surfaces. They can be serviced by several components:
^ Exhaust pipe(s)
^ Three way catalytic converter assembly.
^ Intermediate pipe.
^ Muffler and tail pipe assembly.
^ Seals (if flanged).

CAUTION: If cutting of an exhaust pipe is required for any reason, DO NOT use clamps for assembly. All connections MUST be welded with AISI 409 stainless. Steel material or flanged to maintain the operation of the vehicle emissions system.

COMPONENT INSTALLATION
^ When installing a replacement converter to an existing exhaust or intermediate. Pipe that is flanged, use a new seal and clean flange surfaces. As the exhaust system is being reassembled, be sure to align the components before tightening any hangers to specifications.

^ When installing exhaust parts, make sure there is enough clearance between the hot exhaust parts and pipes, and hoses that would be adversely affected by excessive heat. Check the complete exhaust system, nearby body areas and the trunk lid for broken, damaged, missing or mispositioned parts, and for open seams, holes, loose connections or other deterioration which could permit exhaust fumes to seep into the trunk or passenger compartment. Any damaged areas must be corrected immediately.

CAUTION: If any mispositioning, incorrect installation, or failure of components in the area of the brake system pipes, hoses or wheel cylinders is observed, be sure to check for any brake damage that may have resulted from such a condition and correct as required. Make sure that exhaust system components have adequate clearance from the floor pan to avoid possible overheating of the floor pan and possible damage to the passenger compartment carpets and/or items in the luggage compartment.