Exhaust Muffler Replacement Service Part

Tools Required

SA9168NE Exhaust and Tailpipe Cutter

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Obtain a piece of (non-stretchable) string 18 ½ inches long. Starting from the muffler, place the string along the pipe. Mark the end of the string on the pipe.

Notice: Always use a chain cutter to cut the stainless steel pipe. A torch leaves a rough edge and may warp the pipe.

3. Using a SA9168NE (or equivalent) cut the pipe on the mark.



4. Separate the muffler and tailpipe.
5. Remove the muffler and tailpipe.

Important: The service resonator pipe is designed to attach to either the production or service muffler assembly.

1. Deburr the pipe ends as necessary.



2. Position the service muffler and tailpipe assembly onto the intermediate pipe.
3. Install the rubber isolator to mount hanger.

Notice: Refer to Fastener Notice in the Preface section.




4. Install the service clamp and tighten

Tighten
Tighten the rear muffler pipe service clamp to 45 N·m (33 lb ft).

Exhaust Muffler Replacement Production Assembly

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

Important: The muffler and resonator is not available as a complete assembly. Separate resonator and muffler assemblies are available as service parts.

1. Hoist the vehicle.



2. Remove the rear exhaust pipe flange to intermediate pipe nuts.



3. Separate the hangers from rubber isolators.
4. Remove the muffler and pipe assembly.

1. Position the muffler and resonator assembly to the vehicle and install into the rubber mounts.



2. Install the new gasket onto the exhaust pipe rear flange.

Notice: Refer to Fastener Notice in the Preface section.

3. Assemble the intermediate pipe to exhaust pipe, install new nuts and tighten.

Tighten
Tighten the exhaust pipe-to-intermediate pipe nuts to 30 N·m (22 lb ft).

4. Check the entire exhaust system for leaks.