Removal Procedure

WARNING: This page is about a different car, the 2002 Chevrolet Malibu. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.

Important: A service muffler will be needed when replacing the intermediate pipe on an originally equipped, welded system.

Raise the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
Support the three-way catalytic converter.
Remove the intermediate pipe to the muffler nuts.

Fig 1: Removing Intermediate Pipe To Muffler Nuts
Courtesy of GENERAL MOTORS CORP.
Remove the intermediate pipe from the three-way catalytic converter bolts.
Remove rear sway bar insulator bracket nuts and bracket and position sway bar downward.

Fig 2: Removing Intermediate Pipe From Three-Way Catalytic Converter
Courtesy of GENERAL MOTORS CORP.
Remove the intermediate pipe from the hanger.
Remove the intermediate pipe.

Fig 3: Removing Intermediate Pipe
Courtesy of GENERAL MOTORS CORP.
Remove the three-way catalytic converter seal.
Clean the flange surface.

Fig 4: Removing Three-Way Catalytic Converter Seal
Courtesy of GENERAL MOTORS CORP.