Exhaust Extension Pipe Replacement L61

Notice: Do not over-flex or damage the flex joint when moving the flex joint from the normal mounting position.

Important: A service exhaust muffler will be needed when replacing the exhaust muffler pipe on an factory equipped system.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Support the exhaust muffler.
3. Cut the exhaust muffler pipe just forward of the weld at the front of the exhaust muffler using a suitable exhaust pipe cutter.
4. Remove the muffler insulator from the underbody hanger and remove the exhaust muffler.
5. Deburr the muffler inlet pipe end as necessary.



6. Place a suitable jack stand under the catalytic converter for support.
7. Remove the catalytic converter to exhaust muffler pipe nuts.



8. With the aid of an assistant, separate the exhaust muffler pipe insulators (1) from the underbody hangers.
9. Remove the muffler pipe from the catalytic converter and remove the muffler pipe from the vehicle.
10. Remove and discard the muffler pipe gasket.
11. Clean the catalytic converter flange mating surfaces of any remaining gasket material.

1. Install a NEW exhaust gasket to the service muffler pipe studs.
2. With the aid of an assistant, install the muffler pipe to the catalytic converter and support the muffler pipe.
3. Install the muffler pipe insulators (1) to the underbody hangers.

Notice: Refer to Fastener Notice in the Preface section.




4. Install the catalytic converter to muffler pipe nuts.

Tighten
Tighten the nuts to 30 N·m (22 lb ft).




5. Slide the muffler inlet pipe over the muffler pipe, then install the muffler insulator to the underbody hanger.



6. Install a service muffler clamp to the muffler inlet pipe. Position the clamp approximately 19 mm (¾ in), from the edge of the muffler inlet, with the clamp nuts oriented away from the evaporative emission (EVAP) canister.
7. Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia.
8. While maintaining muffler positioning, tighten the exhaust clamp nuts.

Tighten
Tighten the nuts to 45 N·m (33 lb ft).

9. Lower the vehicle.

Exhaust Extension Pipe Replacement RPOs LE5/LSJ

Notice: Do not over-flex or damage the flex joint when moving the flex joint from the normal mounting position.

Important: A service exhaust muffler will be needed when replacing the exhaust muffler pipe on an factory equipped system.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Support the exhaust muffler.
3. Cut the exhaust muffler pipe just forward of the weld at the front of the exhaust muffler using a suitable exhaust pipe cutter.
4. Remove the muffler insulator from the underbody hanger and remove the exhaust muffler.
5. Deburr the muffler inlet pipe end as necessary.



6. Place a suitable jack stand under the catalytic converter for support.
7. If equipped with regular production option (RPO) LE5, remove the catalytic converter to muffler pipe nuts.



8. If equipped with RPO LSJ, remove the catalytic converter to muffler pipe nuts.



9. With the aid of an assistant, separate the exhaust muffler pipe insulators from the underbody hangers.
10. Remove the muffler pipe from the catalytic converter and remove the muffler pipe from the vehicle.
11. Remove and discard the muffler pipe gasket.
12. Clean the catalytic converter flange mating surfaces of any remaining gasket material.

1. Install a NEW gasket to the service muffler pipe studs.
2. With the aid of an assistant, install the muffler pipe to the catalytic converter and support the muffler pipe.
3. Install the muffler pipe insulators to the underbody hangers.

Notice: Refer to Fastener Notice in the Preface section.




4. If equipped with RPO LSJ, install the catalytic converter to muffler pipe nuts.

Tighten
Tighten the nuts to 30 N·m (22 lb ft).




5. If equipped with RPO LE5, install the catalytic converter to muffler pipe nuts.

Tighten
Tighten the nuts to 30 N·m (22 lb ft).

6. Remove the jack stand from under the catalytic converter.



7. Slide the muffler inlet pipe over the muffler pipe, then install the muffler insulator to the underbody hanger.



8. Install a service muffler clamp to the muffler inlet pipe. Position the clamp approximately 19 mm (¾ in), from the edge of the muffler inlet, with the clamp nuts oriented away from the evaporative emission (EVAP) canister.
9. Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia.
10. While maintaining muffler positioning, tighten the exhaust clamp nuts.

Tighten
Tighten the nuts to 45 N·m (33 lb ft).

11. Lower the vehicle.