Orlando

Exhaust Rear Silencer Replacement

Special Tools

CH-6614 Chain - Type Pipe Cutter

For equivalent regional tools, refer to Special Tools .

Warning: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Warning: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

Caution: Do not bend the exhaust flex pipe more than 10 degrees in any direction. Bending of more than 10 degrees or twisting in a range of ±0.5 degrees will damage the exhaust flex decoupler.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .



2. Remove the 2 exhaust rear silencer hanger insulators (3) from the exhaust rear silencer .
3. Remove the exhaust rear silencer hanger insulators bracket bolt (1) from the exhaust rear silencer end pipe bracket (2).
4. Place the exhaust system on to the rear axle.



5. Note the dent marks (1) around the exhaust pipe.




Note: A second technician is required.

6. Cut the exhaust rear auxiliary muffler (2) from the exhaust rear muffler with the CH-6614 cutter (3) at the marked position (2).
7. Remove the exhaust rear auxiliary muffler.
8. Support the exhaust muffler.




Note: A second technician is required.

9. Cut the exhaust rear muffler from the exhaust muffler with the CH-6614 cutter (2) at the marked position (1).
10. Remove the exhaust rear muffler.

1. In case of reuse of the exhaust parts, check the exhaust pipes at the separating sets for the following conditions:

•	roundness of the exhaust pipe, any deformation in the range of the double-clamp must be eliminated

•	burrs inside and outside the exhaust pipe at the cutting edge, use a file to eliminate

•	rust at the exhaust pipe outside, use sandpaper to eliminate





Note: A second technician is required.

2. Install the exhaust rear silencer (7) to the 2 exhaust rear silencer hanger insulators (6).
3. Install the exhaust pipe clamp (1) and loosely tighten.
4. Install the exhaust rear auxiliary muffler (5).

Caution: Refer to Fastener Caution in the Preface section.

5. Install the exhaust rear auxiliary muffler bracket bolt (3) to the exhaust rear auxiliary muffler bracket (4) and tighten to 25 N·m (18 lb ft).
6. Install the exhaust pipe clamp (2) and loosely tighten.
7. Position the exhaust rear silencer (7).
8. Tighten the exhaust pipe clamp (1) to 30 N·m (22 lb ft).
9. Position the exhaust rear auxiliary muffler (5).
10. Tighten the exhaust pipe clamp (2) to 30 N·m (22 lb ft).
11. Unsupport the exhaust muffler.
12. Lower and unsupport the vehicle.