GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1999 🢒 Firefly (Canada) 🢒 Engine 🢒 Engine Exhaust 🢒 Rear Exhaust System Replacement

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the right rear wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  3. Remove the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement in Rear Suspension.

    4. Object Number: 166026 Size: SH
  4. Remove two nuts and the resonator/muffler/tail pipe assembly (1) from the front pipe/three way catalytic converter (TWC) assembly (2).
  5. Remove one bolt and the hanger from the pipe at the resonator.
  6. Remove three bolts and the hangers from the muffler.

    7. Object Number: 185770 Size: SH
  7. Turn the resonator/muffler/tail pipe assembly counterclockwise.

    8. Object Number: 185773 Size: SH
  8. Pull back the resonator/muffler/tail pipe assembly.

    9. Move the resonator/muffler/tail pipe assembly toward the wheel.

    Remove the resonator/muffler/tail pipe assembly from the vehicle.

  9. Clean the seal mating surfaces.

Installation Procedure

    Object Number: 185780 Size: SH
  1. Slide the resonator/muffler/tail pipe assembly near the wheel opening. Connect the assembly to the vehicle.
  2. Turn the resonator/muffler/tail pipe assembly clockwise and push the assembly forward.
  3. Connect the resonator/muffler/tail pipe assembly, with the new gasket, to the front pipe/TWC assembly and secure with two nuts. Do not fully tighten the nuts.
  4. Install the hanger to the pipe at the resonator and secure the hanger with one bolt. Do not fully tighten the bolt.
  5. Before tightening the fasteners, align all of the system components properly in order to prevent any noise or vibrations.

    6. Tighten

        • Tighten the front pipe/TWC assembly-to-resonator/muffler/tail pipe assembly nuts to 35 N·m (26 lb ft).
        •  Tighten all of the hanger bolts to 15 N·m (11 lb ft).
  6. Install the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement in Rear Suspension.
  7. Install the right rear wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  8. Lower the vehicle.