Tools Required

J 29800 Cut-Off Tool

A service muffler is required when replacing the intermediate pipe/resonator on an originally equipped welded system.

Important: The NEW intermediate pipe/resonator will slide over the remaining portion of the intermediate pipe/resonator.

1. Cut (1) near the edge of the expanded portion of the intermediate pipe/resonator (2) using the J 29800 .



2. Remove the hangers from the intermediate pipe/resonator.
3. Support the following:

•	The intermediate pipe/resonator

•	The catalytic converter




4. Remove the hanger bolts from the tail pipes.
5. With the aid of an assistant, lower the intermediate pipe/resonator and muffler assembly from the vehicle.

1. Loosely install the muffler with a U bolt type clamp to the intermediate pipe/resonator.



2. With the aid of an assistant, raise the intermediate pipe/resonator and muffler assembly into position under the vehicle.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the hanger bolts to the tail pipes.

Tighten
Tighten the rear exhaust hanger bolts to 20 N·m (15 lb ft).




4. Slide the intermediate pipe/resonator over the catalytic converter outlet.
5. Loosely install a U bolt type clamp to the intermediate pipe/resonator.



6. Install the hangers to the intermediate pipe/resonator.
7. Align the system for proper clearances to the underbody. Refer to Exhaust System Alignment .
8. Tighten the U bolt type clamps previously installed in steps 1 and 5.

Tighten
Tighten the U bolt clamp nuts to 40 N·m (30 lb ft).