Tools Required

SA9168NE Chain 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: This new design exhaust system resonator should only be used when resonator requires replacement. If exhaust system intermediate pipe requires replacement, original service part (P/N 21013306) should still be used along with the "Intermediate Pipe" procedure in the previous section of this service manual.

1. Raise the vehicle on the hoist.
2. Measure and mark the intermediate pipe at the location shown in the illustration at a distance of 86 cm (34 in) behind the gasket surface of the catalytic converter flange.
3. Using the SA9168NE or equivalent, cut the intermediate pipe at the marked location.



4. Remove the nuts at the outlet of the catalytic converter to intermediate pipe.
5. Remove the catalytic converter gasket and discard.
6. Remove the resonator from the vehicle.

1. Install the pipe clamp over the outlet end of the resonator.
2. Slide the outlet end of the replacement resonator over the remaining section of the intermediate pipe.



3. Install the new gasket at the outlet end of the catalytic converter.
4. Install the resonator to the catalytic converter outlet flange and install the nuts. The flat portion of the resonator flange should face downward.

Tighten
Tighten the converter flange nuts to 25 N·m (19 lb ft).




5. Refer to the illustration and position the pipe clamp 25 mm (1 in) from the end of the resonator pipe and facing downward.
6. Align the resonator and the muffler to achieve proper clearances shown in step 7, then tighten the clamp.



7. Check the exhaust system alignment and clearance to the heat shields. Rattle noises will occur if any of the following clearances are not sufficient.

•	The resonator should have at least 15 mm (9/16 in) clearance from the heat shields. If necessary, bend the heat shields away in any areas with insufficient clearance.

•	Position the muffler to ensure 19 mm (3/4 in) of clearance between the rear of muffler and muffler ramp (2). If proper clearance cannot be obtained, the intermediate pipe must be shortened at the resonator joint.

•	The muffler hanger block should not contact the hanger screw (1). If necessary, loosen the muffler mounting strap, shift muffler mounting strap forward to eliminate contact, and retighten.

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

8. Start the engine and check for exhaust system leaks.

Tighten
Tighten the exhaust pipe clamp nuts to 41 N·m (30 lb ft).