Exhaust System: Service and Repair
Exhaust System Alignment1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. NOTE: If a new exhaust intermediate pipe-to-muffler assembly Torca(R) clamp is required, a new exhaust intermediate pipe and Torca(R) clamp assembly must be installed.
Loosen all exhaust component fasteners from the exhaust manifolds to the muffler inlet pipe, including the catalytic converter hanger bracket.
3. Push the muffler and tailpipe assembly forward until the collar on the tailpipe hanger bracket is touching the isolator.
4. Make sure the button on the muffler and tailpipe assembly inlet pipe is fully inserted into the L-notch on the exhaust intermediate pipe.
5. Make sure the catalytic converters are fully seated and the notch on the RH catalytic converter is aligned with the button on the LH catalytic converter.
6. Tighten the catalytic converter exhaust Torca(R) clamp to 47 Nm (35 lb-ft).
7. Align the RH catalytic converter (crossover pipe) so that it is parallel to the transmission crossmember. The maximum allowable angle is 1.0 degree.
8. Tighten the catalytic converter hanger bracket bolts to 30 Nm (22 lb-ft).
^ Verify the RH catalytic converter (crossover pipe) is still aligned to the transmission crossmember. Realign as necessary.
9. If not already tight, tighten the catalytic converter-to-exhaust manifold nuts to specification as follows:
^ Tighten the LH lower converter-to-exhaust manifold nut to 20 Nm (15 lb-ft).
^ Tighten the LH upper converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
^ Tighten the LH lower converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
^ Tighten the RH lower converter-to-exhaust manifold nut to 20 Nm (15 lb-ft).
^ Tighten the RH upper converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
^ Tighten the RH lower converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
10. Verify the gap between the RH catalytic converter-to-exhaust intermediate pipe is within specification. The maximum allowable gap is 5 mm (0.20 inch).
11. Slide the exhaust coupler against the button, then tighten the exhaust coupler bolts to specification. Use the following sequence:
^ Tighten the front nut to 47 Nm (35 lb-ft).
^ Tighten the back nut to 47 Nm (35 lb-ft).
^ Tighten the front nut to 47 Nm (35 lb-ft).
12. NOTE: If a new exhaust intermediate pipe-to-muffler assembly Torca(R) clamp is required, a new exhaust intermediate pipe and Torca(R) clamp assembly must be installed.
Tighten the exhaust intermediate pipe-to-muffler and tailpipe assembly exhaust Torca(R) clamp to 47 Nm (35 lb ft).
13. Verify the exhaust system is within specification.
14. Start the engine and check the exhaust system for leaks.