Exhaust System: Service and Repair

REMOVAL

NOTE: Some service procedures require the removal of the entire exhaust system in order to gain better access to certain components for removal and installation. The following procedure explains how to remove the entire exhaust system. Refer to specific procedures if replacing individual exhaust components.

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.

1. Raise vehicle on hoist and apply penetrating oil to fasteners that connect the exhaust system to the exhaust manifold (2.4L)/cross-under pipe (2.7L).
2. Remove ground strap from muffler.
3. Vehicles equipped with 2.4L engine, disconnect downstream oxygen sensor connector.
4. Remove fasteners that attach exhaust system to exhaust manifold/cross-under pipe.

CAUTION: Do not use any tools to remove the rubber isolators-remove by hand only. Soapy water or silicone-based lubricant spray may be used to assist removal installation of isolators. DO NOT use a petroleum-based lubricant on the isolators, as damage to the rubber material can occur.

5. Remove support isolators from muffler supports.
6. Remove exhaust system from vehicle.

NOTE: Band clamps are spot welded to exhaust system. If a band clamp must be replaced, the spot weld must be ground off the exhaust pipe.

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 for the following reasons:
^ 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.

INSPECTION
Inspect the exhaust pipes, catalytic converters, muffler, and resonators for cracked joints, broken welds and corrosion damage that would result in a leaking exhaust system. Inspect the clamps, support brackets, and insulators for cracks and corrosion damage.

NOTE: Slip joint band clamps are spot welded to exhaust system. If a band clamp must be replaced, the spot weld must be ground off.

INSTALLATION

NOTE: Always work from the front to rear of exhaust system when aligning and tightening exhaust system components.

1. Loosely install fasteners that attach exhaust system to exhaust manifold (2.4L) /cross-under pipe (2.7L).
2. Install support isolators to muffler supports.
3. Align exhaust system to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them. Tighten fasteners that attach exhaust system to exhaust manifold (2.4L) /cross-under pipe (2.7L) to 28 Nm (250 inch lbs.).
4. Vehicles equipped with 2.4L engine, reconnect the downstream oxygen sensor connector.
5. Connect ground strap to muffler.
6. Lower vehicle.