Exhaust System: Muffler: Installation

Fig 1: Front Exhaust Pipe And Resonator Module Clamps

Courtesy of DAIMLERCHRYSLER CORP.

1 - FRONT EXHAUST MODULE

2 - FRONT EXHAUST PIPE MODULE CLAMP

3 - RH CATALYTIC CONVERTER

4 - LH CATALYTIC CONVERTER

1. Position front exhaust pipe module clamps (2) on exhaust pipe assembly.
2. Install exhaust pipe assembly into catalytic converters (3 and 4).
   NOTE: Isolators will have an approximately 10° forward angle when installed.
3. Install isolators.
   Fig 2: Muffler And Resonator Assembly

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - BALL FLANGE

   2 - MUFFLER AND RESONATOR ASSEMBLY

   3 - BAND CLAMPS

   4 - ISOLATOR

   5 - RH REAR RESONATOR AND TAILPIPE ASSEMBLY

4. 5.7L Engine - Install LH rear resonator and tailpipe assembly (Refer to EXHAUST SYSTEM/RESONATOR - INSTALLATION) .
   NOTE: Check for proper alignment and clearance to underbody and engine compartment components before tightening clamps.
5. Tighten band clamps to 61 N.m (45 ft. lbs.).
   Fig 3: Tunnel Reinforcement

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - NUTS

   2 - TUNNEL REINFORCEMENT

6. Install tunnel reinforcement (2) and nuts (1). Tighten nuts to 25 N.m (215 in. lbs.)
7. Check clearance between muffler and resonator assembly and fuel tank. Clearance is 14mm (.55 in.) for V8 engine and 16mm (.62 in.) for V6 engine.
8. Check clearance at rear tunnel reinforcement. Clearance is 15 - 20mm (.59 -.78 in.).
9. The tailpipe should be centered in the rear fascia opening.
10. Adjust clearance as necessary.
11. Lower vehicle.
12. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.