Exhaust System: Service and Repair

REMOVING
Exhaust system components may be assembled by means of welds or flanged surfaces. They can be serviced by several components:
^ Exhaust pipe(s).
^ Three Way Catalytic Converter assembly.
^ Intermediate pipe.
^ Muffler and tail pipe assembly.
^ Seals (if flanged).

CAUTION: If cutting of an exhaust pipe is required for any reason, do not use clamps for assembly. All connections must be welded with AISI 409 stainless steel material or flanged to maintain the operation of the vehicle emissions system.

INSTALLING
When installing a replacement converter to an existing exhaust or intermediate pipe that is flanged, use a new seal and clean flange surfaces. On systems that have welded joints, cuts to separate the components must be made directly adjacent to the weld. As the exhaust system is being reassembled, be sure to align the components before tightening any hangers to specifications.

When installing exhaust parts, make sure there is 25 mm clearance to all underbody components. Check the complete exhaust system, nearby body areas and the trunk lid for broken, damaged, missing, or mix-positioned parts, and for open seams, holes, loose connections or other deterioration which could permit exhaust fumes to seep into the trunk or passenger compartment. Any damaged areas must be corrected immediately.

CAUTION: If any mis-positioning, incorrect installation, or failure of components in the area of the brake system pipes, hoses or wheel cylinders is observed, be sure to check for any brake damage that may have resulted from such a condition and correct as required.