Muffler: Service and Repair

Fig. 5 Slip Joint Connection - Typical:

EXHAUST PIPE AND MUFFLERS REMOVAL
1. Raise vehicle on hoist and apply penetrating oil to clamp nuts of component being removed

Fig. 6 Exhaust Pipe And Muffler Support Insulators:

2. Remove clamp and supports at muffler. Remove muffler from exhaust pipe.

Fig. 7 Catalytic Converter To Exhaust Pipe Connection:

3. Disconnect downstream heated oxygen sensor from the catalytic converter pipe.
4. Remove clamp at the catalytic converter to exhaust pipe slip joint. Separate at slip joint.
5. When removing exhaust pipe, raise rear of vehicle to relieve body weight from rear suspension to provide clearance between pipe and lateral arms.

Fig. 8 Catalytic Converter To Exhaust Manifold Connection:

6. Remove catalytic converter to exhaust manifold attaching bolts.
7. Clean ends of pipes and/or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts.

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

NOTE: When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked.

INSTALLATION
1. Assemble catalytic convertor to exhaust manifold ball joint connection.
2. Assemble exhaust pipe to catalytic convertor and the support to the underbody.
3. Install the muffler to exhaust pipe and the sup- ports to the underbody.
4. Working from the front of system;
a. Align and tighten the catalytic convertor to exhaust manifold ball joint bolts.

Fig. 9 Exhaust Clearance:

b. Align each component to maintain position and proper clearance with underbody parts and tighten clamps to specifications.
5. Connect the downstream heated oxygen sensor.