Exhaust System: Service and Repair

ALIGNMENT
The exhaust system hanger's design minimizes noise transfer through the hangers. Vibration and noise will transfer into the vehicle through contact with the body, or hanger restriction. When the exhaust system is at operating temperature, the clamps and insulators should be vertical. The support brackets are horizontal. If repositioning the pipes, heat may be used in front of the rear suspension. The support brackets should be horizontally positioned. Allow the pipes to cool, before touching them. DO NOT use an acetylene torch near the fuel tank. After adjusting the hangers or repositioning the pipes, inspect the entire system for adequate clearance to the frame members and the floor pan (minimum 15 mm or 518 in). The clearance between the mufflers and the spare tire is 35 mm. Tighten all of the clamps, according to the specified torques. Clearance avoids the overheating of the floor pan and possible damage to the passenger compartment carpets. The weight of the exhaust system should evenly distribute across all of the brackets and hangers, as indicated by an equal deflection at each hanger. Some vehicles may exhibit exhaust system misalignment, due to the improper installation of the rear pipe (Y-pipe). When the rear pipe installs low in the assembly, it can pull the exhaust system forward, hitting part of the body. It may also pull the exhaust system close, such that when the vehicle travels over a bump, the exhaust system will contact the body. In order to correct the condition, reinstall the rear pipe, and the exhaust system should move into proper alignment.

COMPONENT REPLACEMENT
The following five components service the exhaust system for this vehicle:
^ Exhaust Manifold pipe/Y-pipe
^ Catalytic Converter
^ Intermediate exhaust pipe/resonator and muffler/tailpipe assembly
^ Muffler and tailpipe assembly
^ Left muffler and tailpipe assembly

NOTE: Remember the following when servicing this system:
^ When replacing the components, use the J 35976 exhaust pipe cutter, or equivalent, to make an cuts.
^ Remove the remaining portions of the intermediate pipe, when installing a replacement intermediate pipe to an existing catalytic converter.