GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

Intermediate Pipe

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REMOVAL & INSTALLATION



Single Exhaust System

CAUTION
Do NOT service the exhaust system while the engine is warm. Extreme heat is generated by engine and may cause severe burns if not allowed to completely cool before servicing.

See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: View of the single exhaust system components-1996 Chevrolet shown



Click image to see an enlarged view

Fig. Fig. 2: Single exhaust system components-1996 Pontiac, Oldsmobile and Buick shown

  1. Raise and safely support the vehicle.
  2.  
  3. Support the muffler, intermediate pipe and catalytic converter with a suitable jack and a piece of wood.
  4.  
  5. Remove any necessary bolts, hangers and insulators.
  6.  

The cuts must be made as close to the weld(s) as possible to ensure adequate overlap for clamping.

  1. Cut the intermediate pipe from the muffler.
  2.  
  3. Support the intermediate pipe and cut the pipe at the converter, then remove the pipe.
  4.  

To install:
  1. Position a new intermediate exhaust pipe, then install a clamp to the original muffler. Do not tighten the clamp yet.
  2.  
  3. Install the bolts to the catalytic converter.
  4.  
  5. Install the insulators, hangers and bolts, as necessary.
  6.  
  7. Tighten the clamp nut to 37 ft. lbs. (50 Nm) and the bolts to the converter to 35 ft. lbs. (47 Nm).
  8.  
  9. Remove the support, then carefully lower the vehicle.
  10.  
  11. Start the engine and check the entire system carefully for leaks.
  12.  

Dual Exhaust System

See Figure 3



Click image to see an enlarged view

Fig. Fig. 3: View of the dual exhaust system components

  1. Raise and safely support the vehicle.
  2.  
  3. Support the muffler, intermediate pipe and catalytic converter with a suitable jack and a piece of wood.
  4.  
  5. Remove any necessary bolts, hangers and insulators.
  6.  
  7. For the Grand Prix and Cutlass Supreme, disconnect the left side muffler crossover pipe from the intermediate pipe.
  8.  

The cuts must be made as close to the right hand muffler as possible to exhaust to ensure adequate overlap for clamping. The cut(s) must be make on the intermediate straight pipe closest to the curve coming out of the left side muffler, but do not cut on the curve or bend.

  1. Cut the intermediate pipe from the right and left side mufflers for the Lumina and Monte Carlo or from the right side muffler for the Grand Prix and Cutlass Supreme.
  2.  
  3. Unfasten the intermediate exhaust pipe bolts from the catalytic converter. Remove the intermediate exhaust pipe from the vehicle.
  4.  

To install:
  1. Position a new intermediate exhaust pipe to the vehicle and support it.
  2.  
  3. Install clamps to the original mufflers. Do not tighten the clamps yet.
  4.  
  5. Install the bolts to the catalytic converter.
  6.  
  7. For the Grand Prix and Cutlass Supreme, fasten the left side cross over pipe to the intermediate pipe.
  8.  
  9. Install the insulators, hangers and bolts, as necessary.
  10.  
  11. Tighten the clamp nuts to 37 ft. lbs. (50 Nm) and the bolts to the converter to 35 ft. lbs. (47 Nm).
  12.  
  13. Remove the support, then carefully lower the vehicle.
  14.  
  15. Start the engine and check the entire system carefully for leaks.
  16.  

 
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