Muffler: Service and Repair

Muffler and Tailpipe

Removal

NOTE: The production muffler and tailpipe assembly is one piece construction. The service muffler and tailpipe is 3-piece construction for partial zero emissions vehicles (PZEV) and 2-piece construction for non-PZEV. It is necessary to cut the production exhaust system to enable the service sections to be fitted. Before cutting any part of the exhaust system, check that the position of the cut is correct in comparison to the service sections to be installed.

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

2. CAUTION: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the exhaust flexible pipe.

Support the exhaust flexible pipe with a support wrap or suitable splint.





3. Remove the 2 exhaust flexible pipe-to-muffler and tailpipe assembly nuts.
^ Discard the nuts and gasket.
4. Detach the tailpipe and muffler assembly from the 2 front exhaust hanger insulators.
5. Cut the exhaust system as indicated in the illustration.





6. Detach the 2 exhaust hanger insulators and remove the front muffler section.
7. Detach the exhaust hanger insulator and remove the rear muffler section.

Installation

CAUTION: The exhaust hanger insulators are constructed from a special material. Use only the correct specification exhaust hanger insulators or damage to the exhaust system may occur.

NOTE: Check the exhaust hanger insulators for damage and fatigue. Install new exhaust hanger insulators as required.

1. NOTE: Do not tighten the service clamp at this time.

Assemble the front muffler service section and service clamp.
2. Position the rear muffler service section and attach the rear exhaust hanger insulator.

3. NOTE: Do not tighten the service clamp at this time.

Using a service clamp, attach the front muffler service section assembly to the rear muffler service section.
^ Attach the 4 exhaust hanger insulators to the front muffler service section assembly.
4. Tighten the service clamps to 47 Nm (35 lb-ft).
5. Using a new gasket, attach the exhaust flexible pipe to the tailpipe and muffler assembly and install the 2 new nuts.
^ Tighten to 47 Nm (35 lb-ft).

6. CAUTION: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the exhaust flexible pipe.

Remove the exhaust flexible pipe support.