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Pelican Technical Article:

Muffler Replacement

Jared Fenton

Time:

2 hours2 hrs

Tab:

$570

Talent:

****

Tools:

13mm wrench, silicone spray, tape measure, sawzall or cut off

Applicable Models:

Volvo C30 (2007-13)

Parts Required:

Muffler, muffler clamp

Hot Tip:

Measure twice, cut once

Performance Gain:

Quieter exhaust

Complementary Modification:

Replace oxygen sensors

The muffler is used to quiet the exhaust exiting the engine. Mufflers tend to rust out over the years, particularly in climates where road salt and other corrosive elements wreak havoc on the exhaust system. This usually results in the exhaust getting louder or a popping type noise coming from the holes rusted though. Replacing the muffler on your C30 is not overly difficult, although I do recommend having a helper nearby to assist you as the muffler is heavy and somewhat cumbersome.

You'll need to jack up the rear of the car and secure it on jackstands for access. See our article on Jacking up Your C30 for more information. Once secured, you'll notice that the pipe leading from the muffler to the catalytic converter is one piece. This makes removal impossible unless you also remove the rear subframe from the car. This is due to the way the car is assembled at the factory.

There is a workaround to the problem. You'll need to cut through the exhaust pipe just before reaching the inlet on the muffler. Volvo makes a specialized clamp that joins the old exhaust pipe with the new muffler. I recommend measuring the length of pipe on the new muffler and use this as the measurement where to cut the old pipe. I recommend using either a Sawzall or a Dremel with a cutoff wheel to cut through the pipe. Use caution when doing so and always use goggles or other eye protection.

Shown here is the rear muffler on the Volvo C30 (green arrow).
Figure 1

Shown here is the rear muffler on the Volvo C30 (green arrow). As you can see, this muffler is starting to display the telltale signs of corrosion along the bottom. This will eventually lead to an exhaust leak.

You'll need to cut through the exhaust pipe along where it leads from the catalytic converter to entering the muffler (green arrow).
Figure 2

You'll need to cut through the exhaust pipe along where it leads from the catalytic converter to entering the muffler (green arrow). I recommend measuring the length of pipe on the new muffler. This will give you an idea of where you should make your cut. You'll also want to factor in the width of the exhaust clamp. There should be about an inch or so cut out to allow the clamp to fit in place.

Once you have made your cut, Loosen and remove the two 13mm bolts (green arrows) holding the exhaust hanger in place.
Figure 3

Once you have made your cut, Loosen and remove the two 13mm bolts (green arrows) holding the exhaust hanger in place. You'll need to transfer the rubber hanger (yellow arrow) off the old muffler if you are re-using it. Use a bit of silicone spray on the hanger to make it easier to slide the muffler on to the hanger.

Do the same for the right side of the car.
Figure 4

Do the same for the right side of the car. Loosen and remove the two 13mm bolts (green arrows) while having a helper support the muffler. Once removed, transfer the hanger (yellow arrow) to the new muffler. Position the new muffler in place and re-attach the hangers. At this point, slide the ends of the exhaust pipes into the muffler clamp and tighten them down. You are now ready to start the car and check for exhaust leaks.

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