Muffler: Service and Repair

Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement (L61, LE5) (2.2L, 2.4L)

Removal Procedure

Caution: Do not over-flex or damage the flex joint when moving the flex joint from the normal mounting position.

Note: A service muffler will be needed when replacing the exhaust resonator pipe on a factory equipped exhaust system.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).





Note: Using an appropriate jack stand, support the exhaust resonator pipe.

2. Remove the insulators (1) from the resonator pipe (2).




3. Remove the insulators (1) from the muffler (3).
4. Using an appropriate tool, cut the resonator pipe (4) forward of the weld at the muffler inlet pipe.
5. Remove the muffler (3) from the vehicle.




6. Remove the resonator pipe nuts (3) from the catalytic converter (4).
7. Remove the resonator pipe (1) and the gasket (2) from the catalytic converter (4).
8. It may be necessary to deburr the resonator pipe and the muffler inlet pipe ends.

Installation Procedure




1. Install the new gasket (2) to the resonator pipe (1).
2. Install the resonator pipe (1) to the catalytic converter (4).

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the resonator pipe nuts (3).

Tighten the resonator pipe nuts to 30 Nm (22 lb ft).




4. Install the resonator pipe (2) to the insulators (1).




5. Install the muffler (3) on to the resonator pipe (4).
6. Install the muffler (3) on to the insulators (1).




7. Install the service clamp (1) on the exhaust muffler (2).
8. Install the service clamp nuts (3).

Tighten the service clamp nuts to 45 Nm(33 lb ft).

9. Remove the support from the exhaust system.
10. Inspect for exhaust leaks and underbody clearance.