Exhaust Muffler Replacement Pickup

Callout	Component Name
Warning: Refer to Exhaust Service Warning in the Preface section. Preliminary Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
1	Exhaust Pipe Nut (Qty: 4) Caution: Refer to Fastener Caution in the Preface section. Tighten (45 N·m (33 lb ft)
2	Exhaust Pipe Clamp Tighten (44 N·m (32 lb ft)
3	Muffler Assembly Note: Always use new exhaust gaskets when removing, installing or replacing exhaust components. Procedure Disengage the exhaust muffler rear pipe from the exhaust isolators.

Exhaust Muffler Replacement LH8

Removal Procedure

Warning: Refer to Exhaust Service Warning in the Preface section.

Warning: Refer to Protective Goggles and Glove Warning in the Preface section.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Measure from the inlet of the resonator towards the front of the vehicle 20 mm (.79 in) (1) and make a mark.
3. Cut the muffler pipe at this mark.



4. Separate the muffler pipe from the insulators (1).
5. With the aid of an assistant remove the muffler pipe (2) from the front exhaust pipe.



6. If replacing the front exhaust pipe, perform the following steps, otherwise proceed to step 7 in the installation procedure.
7. Remove the catalytic converter to the muffler pipe nuts (1).
8. Loosen the muffler pipe clamp (2) at the catalytic converter.



9. Separate the front exhaust pipe from the insulator (1).
10. Remove the front exhaust pipe (2) from the catalytic converters.

Installation Procedure

1. To aid in the installation of the front exhaust pipe and the muffler pipe, add a non petroleum based lubricant to the hangers and the insulators.
2. If replacing the front exhaust pipe perform the following steps, otherwise proceed to step 7.
3. Position the front exhaust pipe to the catalytic converters.
4. Install the front exhaust pipe (2) to the insulators (1).

Caution: Refer to Fastener Caution in the Preface section.




5. Install the front exhaust pipe to the catalytic converter nuts (1).

Tighten
Tighten the catalytic converter nuts to 45 N·m (33 lb ft).

6. Tighten the front exhaust pipe clamp (2) at the catalytic converter.

Tighten
Tighten the front exhaust pipe clamp to 43 N·m (32 lb ft).




7. Install a service clamp over the front exhaust pipe.

Note: The service muffler will come with an oversized inlet to the front exhaust pipe.

8. Install the muffler pipe (2) to the front exhaust pipe.
9. Attach the muffler pipe to the insulators (1).
10. Position the service clamp over the front exhaust pipe joint and tighten the service clamp.

Tighten
Tighten the service clamp to 43 N·m(32 lb ft).

11. Inspect the exhaust system for leaks and underbody clearance.

Exhaust Muffler Replacement LLR

Removal Procedure

Warning: Refer to Exhaust Service Warning in the Preface section.

Warning: Refer to Protective Goggles and Glove Warning in the Preface section.

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




Note: Use care not to over extend the rear brake hose.

2. Complete the following in order to gain clearance to remove the muffler:

2.1.	Remove the lower shock absorber nuts (9) and bolts (8).

2.2.	Remove the right rear leaf spring nut (2) and bolt (1).

2.3.	Wedge a block of wood (5) between the frame (4) and the rear axle (6).




3. Remove the nuts securing the muffler to the catalytic converter.




Note: Do not use oil base lubricants.

4. Apply a soapy solution to the exhaust muffler hanger rod (3) in order to ease the removal of the exhaust hanger (1).
5. Pry the exhaust hanger (1) free from the exhaust muffler hanger rod (3).




Note: Do not use oil base lubricants.

6. Apply a soapy solution to the exhaust muffler hanger rod (2) in order to ease the removal of the exhaust hanger (3).
7. Pry the exhaust hanger (3) free from the exhaust muffler hanger rod  (2).




Note: Do not use oil base lubricants.

8. Apply a soapy solution to the exhaust muffler hanger rod (3) in order to ease the removal of the exhaust hanger (2).
9. Pry the exhaust hanger (2) free from the exhaust muffler hanger rod (3).
10. Complete the following in order to remove the muffler from the vehicle:

10.1.

Slide the muffler rearward from the catalytic converter.

10.2.

Rotate the muffler 90 degrees counterclockwise from the rear.

10.3.

Carefully remove the muffler rearward from the vehicle.

Installation Procedure

1. Complete the following in order to install the muffler to the vehicle:

1.1.	With the muffler turned 90 degrees counterclockwise from the rear, carefully insert the muffler over the rear axle until the flange is near the catalytic converter.

1.2.	Rotate the muffler clockwise 90 degrees to the installed position.

1.3.	Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter.





Note: Do not use oil base lubricants.

2. Apply a soapy solution to the following in order to ease the installation of the hanger (2):

•	The inner diameter of the exhaust muffler hanger (2)

•	The exhaust muffler hanger rod (3)

3. Press the exhaust muffler hanger (3) over the exhaust pipe hanger rod (1).




Note: Do not use oil base lubricants.

4. Apply a soapy solution to the following in order to ease the installation of the hanger (3):

•	The inner diameter of the exhaust muffler hanger (3)

•	The exhaust muffler hanger rod (2)

5. Press the exhaust muffler hanger (3) over the exhaust pipe hanger rod (1).




Note: Do not use oil base lubricants.

6. Apply a soapy solution to the following in order to ease the installation of the hanger (1):

•	The inner diameter of the exhaust muffler hanger (1)

•	The exhaust muffler hanger rod (3)

7. Press the exhaust muffler hanger (1) over the exhaust pipe hanger rod (3).

Caution: Refer to Fastener Caution in the Preface section.




8. Install the nuts securing the muffler to the catalytic converter. Tighten the muffler nuts by hand until each contacts the metal flange.

Tighten
Tighten the nuts to 45 N·m (33 lb ft).




9. Remove the block of wood (5) from between the frame (4) and rear axle (6).
10. Install the right rear leaf spring bolt (1) and nut (2).

Tighten
Tighten the bolt and nut to 85 N·m (63 lb ft).

11. Install the lower shock absorber bolts (8) and nuts (9).

Tighten
Tighten the bolts and nuts to 95 N·m (70 lb ft).

12. Inspect the exhaust system for leaks and underbody contact.
13. Lower the vehicle.

Exhaust Muffler Replacement LH8 EQ9/NA3

Removal Procedure

Warning: Refer to Exhaust Service Warning in the Preface section.

Warning: Refer to Protective Goggles and Glove Warning in the Preface section.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the fuel tank assembly. Fuel Tank Replacement.



3. Remove the catalytic converter nuts (1).
4. Loosen the front exhaust muffler pipe at the catalytic converter clamp (2).
5. Separate the front exhaust muffler pipe hanger from the insulator.
6. Separate the front exhaust muffler pipe from the catalytic converters.



7. Separate the rear exhaust muffler pipe hangers from the exhaust insulators (1).
8. With the aid of an assistant, remove the exhaust muffler pipe (2) from the vehicle.

Installation Procedure

1. To aid in the installation of the exhaust muffler pipe, add a lubricant to the exhaust insulators.
2. Position the front exhaust muffler pipe to the catalytic converters.
3. Install the front exhaust muffler pipe to the front exhaust insulator.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the catalytic converter nuts (1).

Tighten
Tighten the catalytic converter nuts to 45 N·m(33 lb ft).

5. Tighten the exhaust muffler clamp at the catalytic converter (2).

Tighten
Tighten the exhaust muffler clamp to 43 N·m (32 lb ft).




6. Install the exhaust muffler pipe to the rear exhaust insulators (1).
7. Install the fuel tank assembly. Refer to Fuel Tank Replacement.
8. Lower the vehicle.
9. Inspect the exhaust system for leaks and underbody clearance.