American Motors Corporation

Models with six-cylinder engines without catalytic converters

The following instructions do not apply to the 1975 and 1976 Matador with 258 cubic inch engines and manual transmissions, or to all 1975
and 1976 six-cylinder models built for sale in California, all of which
have catalytic converters.

DISASSEMBLING THE SYSTEM

1 Unbolt the two bolts holding the front exhaust pipe flange to the exhaust manifold. Disconnect the front exhaust pipe from the one-piece rear exhaust pipe/muffler assembly by removing the screw holding the clamp at the front-to-rear exhaust pipe joint. The clamp is lo-cated near the pipe's midsection. Spread the clamp and slide the pipe out.

2 Disconnect the tailpipe from the muffler by removing the tailpipe-to-muffler clamp. Remove the tailpipe from the car by loosening and spreading the rear tailpipe clamp. Drop the rear exhaust pipe/muffler assembly by disconnecting it from its hangers. Examine all the brackets, hangers, and clamps, and remove and discard those which are damaged or badly corroded.

REINSTALLING THE SYSTEM

1 Install the brackets and hangers and set the front exhaust pipe into its clamp. Engage the clamp bolt and tighten it just enough to hold the pipe, but still allow it to be maneuvered. Make sure the seal between the front exhaust pipe and the exhaust manifold is in the correct position. Attach the front exhaust pipe to the exhaust manifold, then tighten the two front exhaust pipe-to-exhaust manifold flange bolts.

2 Slide the rear exhaust pipe/muf-fler assembly firmly onto the front ex-haust pipe, and attach the muffler to its hanger assembly. Join the rear exhaust pipe and the front exhaust pipe, and tighten the clamp nut. Slide the tailpipe securely into the rear of the muffler and tighten the clamp bolts at each end of the tailpipe.

3 Go back over the entire system, making sure that each hanger and clamp bolt or nut is securely tightened. The exhaust system must be aligned so that there is no stress on parts and no part can bang against any area of the car.

Models with eight-cylinder engines and single exhaust systems
DISASSEMBLING THE SYSTEM

1 Remove the bolts holding the front exhaust pipe flange to the exhaust manifolds serving the cylinders on the left and right banks of the engine.

2 Disconnect the front from the rear exhaust pipe by removing the clamp at the joint, and remove the front pipe by taking out the clamp holding it at its midsection. Disconnect the rear exhaust pipe from the muffler by removing the clamp at the muffler/exhaust joint.

3 Disconnect the tailpipe from the muffler by removing the tailpipe-to-muffler clamp, and drop the tailpipe by removing the clamp holding it at its rear. Drop the muffler by disconnecting it from its hanger assembly.

4 Examine all the brackets, hangers, and clamps, and remove and discard those which are damaged.

REINSTALLING THE SYSTEM

1 Install the brackets and hangers, and set the front exhaust pipe into its clamp. Engage the clamp bolt and tighten it just enough to hold the pipe, but still permit maneuverability.

2 Make sure the seals between the front exhaust pipe and the exhaust manifolds serving the left and right banks of cylinders are in the correct position. Attach the front exhaust pipe to the left-and right-side exhaust manifolds.

3 Tighten the front exhaust pipe-to-exhaust manifold flange bolts on both the left and right sides. Slide the rear exhaust pipe firmly onto the front exhaust pipe, and attach and tighten the clamp at the joint formed by the two pipes. Slide the muffler onto the rear exhaust pipe, attach it to its hanger assembly, and tighten the clamp at the joint. Slide the tailpipe securely into the rear of the muffler, and position the tailpipe-to-muffler clamp around the joint and tighten the nut.

4 Go back over the entire system, making sure that each hanger and clamp bolt or nut is securely tightened. Be sure the exhaust system is aligned so there is no stress on the parts.

Models with eight-cylinder engines and dual exhaust systems

A dual exhaust system is really two in-dividual systems, each of which is ar-ranged exactly like a single system for each bank of cylinders. Therefore, treat each part of a dual exhaust system as a single system, and follow the instruc-tions previously given for all models with eight-cylinder engines and single exhaust systems.