Exhaust Resonator: Service and Repair

Resonator





Removal

NOTICE: Do not use oil or grease-based lubricants on the insulators. They may cause deterioration of the rubber.

NOTICE: Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. NOTICE: Only use hand tools when removing or installing the spring nuts or damage may occur to the resonator flange studs.

NOTE: When loosening the resonator spring nuts, alternately loosen the nuts from side to side.

Remove and discard the two 8-mm resonator spring nuts.

3. NOTICE: Remove the resonator-to-muffler gasket by simultaneously pulling up and twisting the gasket off the pipe. Do not pry under the gasket or damage to the flange may occur.

Detach the 2 resonator exhaust hangers and remove the resonator.

- Discard the gasket.

Installation

1. Inspect the resonator flange studs for damage.
- If damaged, replace stud(s), or if stud comes out when removing nut(s), replace the stud(s).

2. If replacing the resonator flange stud(s), use the C-Frame and Screw Installer/Remover to push the 8-mm stud(s) out of the flange.





3. NOTE: When positioning the new 8-mm stud in the resonator flange, make sure to line up the new stud seat knurls with witness knurl grooves in the resonator flange.

If replacing the resonator flange stud(s), use a C-clamp and a deep well socket to push the 8-mm stud fully into the flange.

- Make sure the stud is fully and evenly seated into the flange.





4. NOTICE: Replace the gasket by hand. Do not rotate the gasket back and forth during installation. Doing so may lessen the gaskets ability to seal and stay correctly positioned during assembly.

NOTE: Thoroughly clean the sealing surfaces of the flanges using a finishing pad. Inspect the cleaned sealing surface for nicks and scratches and replace as necessary.

Install a new resonator-to-muffler gasket.

5. Install the resonator and attach the 2 resonator exhaust hangers.

6. Install the 2 new 8-mm resonator-to-muffler spring nuts and alternately tighten RH side to LH side in sequence in 3 stages:
- Stage 1: Tighten to 5 Nm (44 lb-in).

- Stage 2: Tighten to 10 Nm (89 lb-in).

- Stage 3: Tighten to 17 Nm (150 lb-in).