Exhaust Pipe: Service and Repair

Exhaust Manifold Pipe Replacement

Removal Procedure

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.

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.





1. Raise and support the vehicle. Refer to Vehicle Lifting.
2. Remove the four nuts securing the catalytic converter to the exhaust manifold pipe.

Notice: Do not over-flex or damage the decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.

3. Position the exhaust system rearward, enough to allow the studs located in the front of the catalytic converter to clear the exhaust manifold pipe.
4. Remove the catalytic converter gasket. Do not reuse the gasket.





5. Remove the two nuts attaching the exhaust manifold pipe to the right exhaust manifold.
6. Remove the exhaust manifold pipe and the gasket. Do not reuse the gasket.

Installation Procedure

Notice: When inspecting or replacing exhaust systems components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floorpan and possible damage to the passenger compartment insulation and trim materials.





1. Place a NEW exhaust manifold pipe gasket over the right exhaust manifold studs.
2. Position the exhaust manifold pipe to the right exhaust manifold.

Notice: Use the correct fastener for the correct location. replacement fasteners requiring the use of 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 two nuts attaching the exhaust manifold pipe to the right exhaust manifold.
^ Tighten the exhaust manifold pipe nuts to 40 Nm (30 ft. lbs.).





4. Place a NEW catalytic converter gasket over the catalytic converter studs.

Notice: Do not over-flex or damage the decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.

5. Position the catalytic converter to the exhaust manifold pipe.
6. Install the four nuts in order to secure the catalytic converter to the exhaust manifold pipe.
^ Tighten the catalytic converter nuts to 25 Nm (18 ft. lbs.).
7. Lower the vehicle.