The exhaust system design varies according to the model designation and the intended use of the vehicle.

In order to secure the exhaust pipe to the exhaust manifold, the exhaust system utilizes a flange and seal joint coupling. A flange and gasket coupling secures the catalytic converter assembly to the muffler assembly.

Hangers suspend the exhaust system from the underbody, allowing some movement of the exhaust system and disallowing the transfer of noise and vibration into the vehicle.

Heat shields protect the vehicle from the high temperatures generated by the exhaust system.

Notice: The three-way catalytic converter requires the use of unleaded fuel only. Using leaded fuel will damage the converter and other emission system components.

The catalytic converter, an emission control device, attaches to the engine exhaust system in order to reduce hydrocarbon, carbon monoxide, and nitrogen oxide emissions from the exhaust gas. The catalytic converter and the exhaust manifold pipe are an assembly. The catalyst, in the catalytic converter, is not serviceable.

1. Inspect the following for cracked joints, broken welds and corrosion damage:

•	Inspect the exhaust pipes.

•	Inspect the seals.

•	Inspect the catalytic converter.

•	Inspect the muffler.

2. Inspect the following for stripped or corroded bolt threads:

•	Inspect the clamps.

•	Inspect the brackets.

•	Inspect the insulators.

3. Inspect the exhaust system, including the heat shields, to ensure that they are free from leaks, binding, grounding and excessive vibration. The following conditions commonly cause these problems:

•	Loose flange bolts.

•	Loose seals.

•	Loose heat shields.

•	Loose brackets.

•	Loose pipes.

4. If these problems exist, inspect the exhaust system components and alignment.
5. Align the system and replace damaged components, as necessary.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

An accumulation of dirt and corrosion may make removing exhaust components difficult. Applying a penetrating oil on the threads of the bolts may assist in the removal of these components.

Notice: Replacement of exhaust system parts must be OEM standard to ensure that the vehicle operates as designed.

When installing exhaust components, inspect the exhaust system for proper alignment. Misaligned components commonly cause rattles, noise and vibrations in the exhaust system. During system alignment, leave all of the bolts or nuts loose, until all of the parts are properly aligned. After properly aligning the parts, tighten the bolts or nuts from the front to the rear.

In order to maintain the alignment of the exhaust system, replace any damaged exhaust system hangers, hanger brackets, and clamps.

Notice: When jacking or lifting the vehicle from the frame side rails, be certain lift pads do not contact the three-way catalytic converter as damage to the converter will result.

Important: 

1. When exhaust system service requires removing and replacing an oxygen sensor, refer to Oxygen Sensor Service in Engine Controls.
2. Replace the tailpipe when replacing the muffler.
3. Always use new nuts when installing the exhaust pipe to the exhaust manifold.
4. Before installing the new nuts, clean the exhaust manifold stud threads with a wire brush.