Repair Procedure

This bulletin involves aligning the exhaust pipe in the tunnel and straightening the tunnel heat shield.

1. Measure the clearance between the intermediate ("I") pipe and shield/floor pan in the areas of contact. Record this data on the repair order for future use.





2. Inspect the catalyst assembly to ensure that the alignment button is fitted into the notch on the "I" pipe (Figure 1).

3. If the alignment button is fitted into the notch and the "I" pipe is not in the center of the tunnel, remove the alignment button to allow centering of the "I" pipe in the tunnel by the following procedure:

^ Separate the "I" pipe from the portion of the pipe with the alignment button.

^ Using a grinder or chisel, remove the alignment button to allow the pipe to turn easily within the "I" pipe.

4. Inspect the rubber isolators on the "I" pipe and muffler for side to side movement, by pushing on the pipe. The rubber isolators are designed for forward and rearward movement only. If the exhaust system cannot be centered as described in steps 2 and 3, replace the rubber isolator with P/N 04495951.

5. If the "I" pipe is correctly aligned down the center of the tunnel and still contacts the heat shield, the heat shield must be replaced.





**6. Remove the rear three bolts of the heat shield (Figure 2).

7. Loosen the front two bolts and slide the heat shield off (Figure 2).

8. Slide the new heat shield (P/N 05278028AB) into place over the two front bolts. Ensure that the heat shield is fully seated on the two bolts.

9. Install the rear center bolt and torque to 3.7 N.m (33 in.-lb.).

10. Torque the two front bolts to 3.7 N.m (33 in.-lb.).

11. Install the remaining two rear bolts and torque to 3.7 N.m (33 in.-lb.).

12. Install the intermediate pipe, if removed, and torque clamps to 74.5 N.m (55 ft.lb.).

13. Test drive the vehicle and listen for the noise/vibration. If the noise/vibration is still apparent, proceed to step 14. If the noise/vibration is gone, no further action is needed.**

14. Inspect the areas of contact and bend the shield to provide more clearance:





^ Measure between the "I" pipe and the heat shield in the areas showing contact marks, there should be a minimum clearance of 25 mm (Figure 3).

In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3).

^ Measure between the heat shield and the floor pan in the areas showing contact marks, there should be a minimum of 5 mm clearance (Figure 3).

^ In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3).

CAUTION:
DO NOT BEND THE HEAT SHIELD TO THE EXTENT THAT IT CONTACTS THE BODY OR BECOMES LOOSE.