Exhaust System: Service and Repair

Exhaust System Replacement (L-38)

Removal Procedure
Servicing of the mufflers, resonator, or pipe requires the replacement of the exhaust system as a complete one-piece unit.

Caution: Refer to Exhaust Service Caution in Service Precautions.

Caution: Refer to Protective Goggles and Gloves Caution in Service Precautions.





1. Raise and support the vehicle.
2. Remove the oxygen sensor wiring harness heat shield.
3. Disconnect the Heated Oxygen Sensor (H02S) at the pigtail.
4. Remove the H02S if replacement is necessary.
5. Remove the 4 nuts securing the catalytic converter to the rear exhaust manifold pipe.
6. Remove the catalytic converter gasket. Do not reuse the gasket.
7. Suitably support the exhaust system.





8. Remove the 2 bolts securing the center exhaust hangers to the rear suspension support brackets.





9. Remove the 2 bolts securing the rear exhaust hanger brackets to the rear compartment rails.
10. With the aid of an assistant, lower the exhaust system.





11. Remove the 2 nuts securing the rear exhaust hangers to the rear exhaust hanger brackets.
12. Remove the rear exhaust hanger brackets from the rear exhaust hangers.

Installation Procedure





1. Install the rear exhaust hanger brackets to the rear exhaust hangers.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the 2 nuts securing the rear exhaust hangers to the rear exhaust hanger brackets.
^ Tighten the rear exhaust hanger nuts to 30 Nm (22 ft. lbs.).






Notice: Refer to Exhaust System Inspection Notice in Service Precautions.

3. Place a NEW catalytic converter gasket over the catalytic converter studs.

Notice: Refer to Flex Decoupler Notice in Service Precautions.

4. With the aid of an assistant, raise the exhaust system into position, aligning the catalytic converter with the rear exhaust manifold pipe.
5. Finger tighten the 4 nuts to the catalytic converter studs.





6. Install the 2 bolts securing the rear exhaust hanger brackets to the rear compartment rails.
^ Tighten the rear exhaust hanger bolts to 50 Nm (37 ft. lbs.).





7. Install the 2 bolts securing the center exhaust hangers to the rear suspension support brackets.
^ Tighten the center exhaust hanger bolts to 30 Nm (22 ft. lbs.).
8. Tighten the 4 catalytic converter nuts previously installed in step 5.
^ Tighten the catalytic converter nuts to 25 Nm (18 ft. lbs.).
9. Install the 1-102S.
10. Remove the oxygen sensor wiring harness heat shield.
11. Lower the vehicle.