Intermediate Pipe (Service Replacement)

REMOVAL





WARNING: Make sure vehicle is properly supported and squarely positioned prior to lifting. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed. Make sure hoist does not contact fuel or brake lines.

1. Raise vehicle squarely on a lift.

NOTE: When replacing the intermediate pipe, it will be necessary to remove or cut off the muffler at the dimension provided. Removing the muffler and disconnecting the three way catalytic converter allows for intermediate pipe replacement without lowering the rear suspension. It will be necessary to complete an alignment check if the rear suspension is lowered.

2. Remove the fasteners at rear of three way catalytic converter.

CAUTION: Do not bend the front exhaust pipe or hanger attached to the engine stiffening bracket when servicing the front exhaust pipe and/or three way catalytic convertor. Bending the bracket or pipe may cause premature failure.





3. Remove three way catalytic converter gasket and discard.

NOTE: Always use a chain cutter to cut the stainless steel exhaust system pipes. A torch leaves rough edge and warps the pipe end, preventing good exhaust system sealing.





4. Using chain cutter, cut the muffler inlet pipe off 62 mm (2 7/16 inch) forward of the weld. If a service muffler has been installed, separate the joint.
5. Remove the intermediate pipe support bracket isolator and the intermediate pipe.

INSTALLATION
1. Position the service intermediate pipe under the vehicle.





2. Install the sleeve, if required, on the intermediate pipe outlet and the clamp on the muffler inlet.

NOTE: The sleeve furnished with each muffler is required when both a service muffler and service intermediate pipe are installed.

3. Insert the intermediate pipe outlet into the muffler inlet.

NOTE: The intermediate pipe must extend a minimum of 32 mm (1 1/4 inch) into the muffler inlet pipe.

4. Clean the intermediate pipe-to-three way catalytic converter outlet pipe.





5. Install a new gasket on the three way catalytic converter outlet pipe.
6. Make sure the three way catalytic converter gasket is properly located and install the three intermediate pipe-to-three way catalytic converter fasteners. Torque to 31 Nm (23 ft. lbs.).
7. Check the entire exhaust system for alignment and leaks.