ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Muffler

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REMOVAL & INSTALLATION



See Figure 1



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Fig. Fig. 1: Rear of the catalytic converter-to-muffler-2.2L gasoline engine shown

Safety glasses should be worn at all times when working on or near the exhaust system. Older exhaust systems will almost always be covered with loose rust particles which will shower you when disturbed. These particles are more than a nuisance and could injure your eye.

  1. Raise and support the front of the truck safely using jackstands.
  2.  
  3. Spray all fasteners which are to be disconnected using a penetrating oil.
  4.  
  5. Remove the catalytic converter-to-muffler flange bolts and separate the items.
  6.  
  7. Remove the intermediate and rear tail pipe-to-bracket clamp nuts/bolts.
  8.  
  9. Remove the muffler bracket-to-chassis bolts and lower the muffler from the vehicle.
  10.  
  11. Coat the slip joints with GM type sealing compound 1051249 or equivalent, and loosely install the components onto the vehicle.
  12.  
  13. After aligning the components, tighten the connecting bolts and clamps, taking care not to distort the sealing surfaces.
  14.  

When torquing the exhaust system connectors, be careful not to overtighten the pipe clamps.

  1. Remove the jackstands and carefully lower the vehicle.
  2.  
  3. Start the engine and check for exhaust leaks.
  4.  

 
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