Exhaust Muffler Replacement 2.2L

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Remove the catalytic converter to muffler flange nuts.



3. Remove the insulator from the tail pipe hanger.



4. Remove the insulator from the muffler and the tail pipe hanger.
5. Remove the muffler and gasket from the vehicle.

1. Install a new gasket and the muffler to the vehicle.
2. Install the insulator to the muffler and tail pipe hanger.



3. Install the insulator to the tail pipe hanger.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the catalytic converter to muffler flange nuts.

Tighten
Tighten the catalytic converter to muffler flange nuts to 40 N·m (30 lb ft).

5. Lower the vehicle.

Exhaust Muffler Replacement 4.3L Pickup

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Remove the catalytic converter to muffler flange nuts.



3. Remove the insulator from the tail pipe hanger.



4. Remove the insulator from the muffler and the tail pipe hanger.
5. Remove the muffler and gasket from the vehicle.

1. Install a new gasket and the muffler to the vehicle.
2. Install the insulator to the muffler and the tail pipe hanger.



3. Install the insulator to the tail pipe hanger.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the catalytic converter to muffler flange nuts.

Tighten
Tighten the catalytic converter to muffler flange nuts to 40 N·m (30 lb ft).

5. Lower the vehicle.

Exhaust Muffler Replacement 4.3L Utility

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Remove the catalytic converter to muffler flange nuts.



3. Remove the insulator from the tail pipe hanger.



4. Remove the insulators from the muffler hanger (4-door utilities).



5. Remove the insulator from the muffler and the tail pipe hanger.
6. Remove the muffler and the gasket from the vehicle.

1. Install a new gasket and the muffler to the vehicle.
2. Install the insulator to the muffler and tail pipe hanger.



3. Install the insulators to the muffler hanger (4-door utilities).



4. Install the insulator to the tail pipe hanger.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install to catalytic converter to the muffler flange nuts.

Tighten
Tighten the catalytic converter to muffler flange nuts to 40 N·m (30 lb ft).

6. Lower the vehicle.