Exhaust Pipe: Service and Repair

Intermediate Pipe Replacement

Removal Procedure





Notice: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.

Important: A service muffler will be needed when replacing the intermediate pipe on an originally equipped, welded system.

1. Raise the vehicle. Refer to Vehicle Lifting.
2. Support the three way catalytic converter.
3. Cut the intermediate pipe (1) at the muffler (2).





4. Remove the intermediate pipe bolts at catalytic converter.





5. Remove the intermediate pipe from the hanger.
6. Remove the intermediate pipe.





7. Remove the three way catalytic converter seals.
8. Clean the flange surface.

Installation Procedure





1. Install the three way catalytic converter seals.





2. Install the intermediate pipe to the hanger.





Notice: Refer to Fastener Notice in Service Precautions.

3. Install the intermediate pipe bolts to catalytic converter.
^ Tighten the intermediate pipe bolts to 30 Nm (22 ft. lbs.).





4. Weld the muffler (2) to the intermediate pipe (1).
5. Lower the vehicle.