Mid Muffler Replacement

Mid Muffler Replacement

Tools Required

SA9168NE Exhaust and Tailpipe Cutter

Removal Procedure

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.

1. Raise and support the vehicle. Refer to Vehicle Lifting.




2. Obtain a piece of (non-stretchable) string 135 mm (5.3 in) long. Starting from the muffler, place the string along the pipe. Mark the end of the string on the pipe.

Notice: Always use a chain cutter to cut the stainless steel pipe. A torch leaves a rough edge and may warp the pipe.

3. Using the SA9168NE (or equivalent), cut the pipe on the mark.




4. Remove the rear exhaust pipe flange to intermediate pipe nuts.




5. Separate the hanger from the rubber isolators.
6. Remove the resonator and pipe assembly.
7. Fully remove the gasket material and discard.

Installation Procedure





Important: The service resonator pipe is designed to attach to either the production or service muffler assembly.

1. Deburr the pipe ends as necessary.




2. Position the service intermediate pipe and resonator assembly on the rear muffler pipe.





Notice: Refer to Fastener Notice.

3. Install the new gasket onto the front pipe flange. Position the resonator pipe to flange. Install the nuts and tighten.

Tighten the resonator pipe-to-flange nuts to 30 N.m (22 lb ft).




4. Install the service clamp and tighten.

Tighten the rear muffler pipe service clamp to 45 N.m (33 lb ft).




5. Install the rubber isolator to mount hanger.