Tools Required

SA9168NE Exhaust and Tailpipe Cutter

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

Important: If both the intermediate pipe and muffler assembly are being replaced, the intermediate pipe must be shortened at the outlet end so the muffler inlet can fit over it. Cut the intermediate pipe right behind the up-sized outlet end.

1. Raise the vehicle squarely on a lift.



2. Remove the nuts at the outlet of the catalytic converter to intermediate pipe.
3. Remove the catalytic converter gasket and discard.




Important: Always use a chain cutter to cut the stainless steel exhaust system pipes.

Important: The replacement intermediate pipe should be used as a guide to precisely locate the cut location on the pipe section. Hold the replacement pipe to the existing section and mark the cut location BEFORE cutting or removing the old pipe.

4. Using the SA9168NE or equivalent, cut the intermediate pipe in front of the rear suspension. Locate the center (1) of the approximately 100 mm (4.0 in.) long straight section, mark the pipe, and make cut.
5. Disengage the rubber isolator from the hanger rod on the intermediate pipe and remove the pipe.

1. Position the service intermediate pipe under the vehicle.
2. Slide the outlet end of the intermediate pipe over the remaining section of muffler inlet pipe.
3. Install the new gasket at the outlet of the catalytic converter.
4. Install the intermediate pipe to the converter outlet using 3 fasteners.

Tighten
Tighten the intermediate pipe-to-converter nuts to 25 N·m (19 lb ft).

5. Install the rubber isolator to the hanger rod on the intermediate pipe.




Important: Locate the muffler clamp 25 mm (1 in) (2) from the end of the intermediate pipe and position the clamp with the U-bolt facing away from the fuel tank.

6. Install the pipe clamp at the outlet end of the intermediate pipe.
7. Align the muffler and the intermediate pipe, then tighten the clamp.

Tighten
Tighten the intermediate pipe to 41 N·m (30 lb ft).





Important: Ensure that after installing the replacement exhaust sections that the system has not shifted rearward allowing contact between the hanger bracket screw (1) and the hanger block. This will cause noise. Loosen the muffler strap and shift forward on the muffler to eliminate contact - retighten.

8. Check the exhaust system for alignment and clearance to heat shields.

Tighten
Tighten the muffler strap around the muffler to 22 N·m (16 lb ft).

Notice: Position the muffler to ensure that there is 19 mm (3/4 in) of clearance between the muffler and muffler ramp. If proper clearance can not be obtained, the intermediate pipe must be shortened.

9. Start the engine and check for leaks.