GM 15283438
Muffler

The replacement of the exhaust extension pipe (RPO L61) should start by loading and supporting the vehicle. Use a suitable Exhaust Pipe cutter to cut the exhaust Muffler pipe at a point just in front of its weld near the front of the exhaust Muffler while supporting the Muffler. First remove the Muffler insulator from the underbody hanger then separate the exhaust Muffler from its installation position. Sanitize the Muffler inlet pipe end after cleaning it and then implement a suitable jack stand beneath the Catalytic Converter to provide support. Several team members should detach the exhaust Muffler pipe nuts from the Catalytic Converter to allow separation of the exhaust Muffler pipe insulators from the underbody hangers. Cutter the Muffler pipe loose from the Catalytic Converter and remove it from the vehicle before discarding the gasket. Use a suitable tool to remove any remaining gasket material from the Catalytic Converter flange mating surfaces. The installation process begins with a new exhaust gasket mounted on the service Muffler pipe studs before you and an assistant jointly install the pipe onto the Catalytic Converter while providing support. You should insert the Muffler pipe insulators to underbody hangers followed by securing the Catalytic Converter Muffler pipe connection using 30 n.m (22 lb ft) torque. Place the Muffler inlet pipe over the Muffler pipe before fitting the underbody hanger with the Muffler insulator. Place a service Muffler clamp on the Muffler inlet pipe at a 19 mm (3/4 in) distance from its edge while positioning the clamp nuts in the direction opposite to the evap canister. Tire the Muffler against the underbody while positioning it to the rear fascia and underbody before clamping its nuts to 45 n.m (33 lb ft). Finally, lower the vehicle.

In order to replace the exhaust Muffler with resonator, exhaust, and Tail Pipe on a 2.2l engine, first lift the vehicle and safely let it rest using the well-suited jack stand to support the exhaust resonator pipe. Pull off the insulators from the resonator pipe and from the Muffler. Cut forward of the weld at the Muffler inlet pipe by using an appropriate tool and then remove the Muffler from the vehicle. Subsequently, remove the resonator pipe nuts from the Catalytic Converter and pull out the resonator pipe and the gasket from the Catalytic Converter . It could be necessary to deburr the ends of the resonator pipe as well as the Muffler inlet pipe. For installation, be sure to put the new gasket on the resonator pipe and hook the resonator pipe to the catalytic convertor before tightening the resonator pipe nuts to 30 nm (22 lb ft). Attach the connect the resonator pipe to the insulators and mount the Muffler to the resonator pipe and to the insulators. Use the service clamp to attach the exhaust Muffler but then tighten the service clamp nuts to 45 nm (33 lb ft). Finally, take off support for the exhaust system, look for exhaust leaks and clearance underbody, and lift the vehicle.

Tighten the exhaust clamp nuts to 45 Nm (33 ft. lbs.) while maintaining muffler positioning.

Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia, then while maintaining muffler positioning, tighten the exhaust clamp nuts to 45 Nm (33 ft. lbs.). Finally, lower the vehicle.

With the help of an assistant, remove the resonator pipe and the muffler as one unit from the vehicle.

Lower the vehicle.

Slide the muffler inlet pipe over the muffler pipe and install the muffler insulator to the underbody hanger.

Lower the vehicle.