WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION.

Muffler Assembly, Single

2.3L Engine

Removal

1. Remove both lower shock absorber attachments.

2. Raise vehicle at the frame lift points to allow the axle full downward travel. This will provide the clearance necessary to remove and replace the muffler and pipe. Refer to Section 00-02.

3. Remove the rear converter-to-muffler pipe flange connection retaining nuts.

4. Remove the the tail pipe from the rear hanger.

5. Remove the retaining screws from the rear muffler support bracket.

6. Slide the muffler assembly rearward to disconnect it from the catalytic converter.

7. Replace any damaged parts.

Installation

NOTE: The muffler heat shield is clamped to the muffler body. A new service clamp must be used for reassembly.

1. Position the muffler assembly over the rear axle and install the rear muffler support bracket. Tighten to 14-20 Nm (10-15 lb-ft).

2. Position the muffler inlet pipe flange to the converter flange. Install but do not tighten the retaining nuts.

3. Install tail pipe on the rear hanger.

4. Align the exhaust system to conform to the proper clearance specifications. Starting from the muffler inlet pipe connection, tighten all nuts and screws to specification. Refer to illustration.

5. Assemble lower shock absorber attachments. Tighten to 79-95 Nm (55-70 lb-ft).

6. Check the system for leaks and lower vehicle.