Muffler: Service and Repair

REMOVAL PROCEDURE





1. Raise the vehicle.

CAUTION:
^ Always wear protective goggles and gloves when removing exhaust parts as failing rust and sharp edges from worn exhaust components could result in serious personal injury.
^ In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

NOTICE: When jacking or lifting the vehicle from the frame side rails, be certain lift pads do not contact the three-way catalytic converter as damage to the converter will result.

An accumulation of dirt and corrosion may make removing exhaust components difficult. Applying a penetrating oil on the threads of the bolts may assist in the removal of these components.

2. Support the vehicle with safety stands.
3. Support the muffler assembly.
4. Remove the three nuts connecting the muffler assembly to the catalytic converter assembly.
5. To aid in the removal of the muffler assembly, lubricate the rubber hangers with rubber lubricant GM P/N 12345884.





Remove the muffler assembly from the front hanger.





6. Remove muffler assembly from the rear hanger.





7. Remove the muffler assembly from the tailpipe hanger.
8. Remove the muffler assembly from the vehicle.

INSTALLATION PROCEDURE





1. To aid in the installation of the muffler assembly, lubricate the rubber hangers with rubber lubricant GM P/N 12345884.
Install the muffler assembly into the vehicle.

NOTICE: Replacement of exhaust system parts must be OEM standard to ensure that the vehicle operates as designed.

When installing exhaust components, inspect the exhaust system for proper alignment. Misaligned components commonly cause rattles, noise and vibrations in the exhaust system. During system alignment, leave all of the bolts or nuts loose, until all of the parts are properly aligned. After properly aligning the parts, tighten the bolts or nuts from the front to the rear.

In order to maintain the alignment of the exhaust system, replace any damaged exhaust system hangers, hanger brackets, and clamps.

IMPORTANT:
^ When exhaust system service requires removing and replacing an oxygen sensor, refer to H02S Replacement in Powertrain Management.
^ Replace the tailpipe when replacing the muffler.
^ Always use new nuts when installing the exhaust pipe to the exhaust manifold.
^ Before installing the new nuts, clean the exhaust manifold stud threads with a wire brush.

2. Connect the muffler assembly to the tailpipe hanger.





3. Connect the muffler assembly to the rear hanger.





4. Connect muffler assembly to the front hanger.





5. Install the three nuts to connect the muffler assembly to the catalytic converter assembly.
^ Tighten the nuts to 40 Nm (30 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.