For 1990-2009 cars

### Exhaust System

A flex coupling is used to connect to the exhaust pipe to the exhaust manifold connections. The flex coupling allows angular movement between the engine and the exhaust system.

The exhaust system is supported by free-hanging rubber mountings. The rubber mountings permit some movement of the exhaust system. They minimize the transfer of noise and vibration into the passenger compartment.

During muffler replacement, also replace the tailpipe.

Notice: When jacking or lifting the vehicle from the frame side rails, be certain that the lift pads do not contact the catalytic converter. This may damage the converter.

Periodic maintenance of the exhaust system is not required; however, inspect the catalytic converter, the pipes and the muffler, if the car is raised for other service.

### Diagnosis

Misaligned parts may cause rattles and noise vibrations in the exhaust system. When aligning the system, leave all bolts or nuts loose until all parts are properly aligned. Then tighten the bolts or nuts working from the front to the rear.

Exhaust system performance complaints, such as excessive back pressure, are noticeable by their effect on engine performance. However, other faulty vehicle components may have the same effect.

### Component Replacement

Welds or flanged surfaces may be used to assemble exhaust system components. The following components can be serviced by welds or flanged surfaces.

• | Exhaust pipe(s)

• | Intermediate Pipe

• | Muffler and Tail Pipe Assembly

• | Seals (if flanged)

• | Three way catalytic converter Assembly

Notice: Do not use clamps for assembly if cutting the exhaust pipe is required. Weld all connections with AISI 409 stainless steel material or flange connections in order to maintain the operation of the vehicle emissions system.

Use a new seal and clean flange surfaces when installing a replacement converter to an existing exhaust or intermediate pipe that is flanged.

On systems that have welded joints, cuts must be made directly adjacent to the weld.

Align the components before tightening any hangers to specification, as the exhaust system is being reassembled.

### On-Vehicle Service

There must be enough clearance between all of the hot exhaust parts and pipes, and hoses when installing exhaust parts.

Check the complete exhaust system, nearby areas and the trunk lid for any of the following conditions which may permit exhaust fumes to seep into the trunk or passenger compartment:

• | Damaged Parts

• | Missing Parts

• | Mis-positioned Parts

• | Loose Connections

• | Other Deterioration

Correct any damaged areas immediately.

Notice: If there is any mis-positioning, incorrect installation, or failure of components in the brake system pipes, hoses, or wheel cylinders, check for brake damage. The exhaust system components must have adequate clearance from the floor pan to avoid overheating of the floor pan, damage to the passenger compartment carpets and damage to items in the luggage compartments.