REMOVAL & INSTALLATION
The muffler and tailpipe on most Toyotas are one piece and should be replaced as a unit. The muffler includes a lead-in pipe to the muffler. All Toyota exhaust components bolt together with gaskets at the joints; no welding is involved.
- Elevate and firmly support the rear of the vehicle.
- On some models you will need to remove the oxygen sensor. Unbolt the oxygen sensor and remove it. Protect the tip of the sensor from damage and do not place it on or near any petroleum based solvents. This includes putting it on a greasy rag.
- Disconnect the nuts holding the muffler and/or tailpipe to the adjacent pipes.
- Remove or disconnect the clamps and supports holding the pipe at either end. Leave the supports closest to the center in place until last.
- Remove the last supports or hangers and lower the unit to the ground. At NO TIME should the muffler be allowed to hang partially supported; the leverage can break the next component in line.
If the muffler or tailpipe is being replaced due to rust or corrosion, adjacent pipes should be checked for the same condition. The pieces tend to age at about the same rate.
- Check the rubber supports that hang the exhaust, they have a tendency to stretch and crack with age, replace if necessary.
- Lift the new unit into place and loosely attach the hangers or supports to hold it in place. Allow some play to adjust the muffler.
- Using new gaskets, connect each end to the adjoining pipe. Tighten the joint bolts and nuts to 29-32 ft. lbs. (39-43 Nm).
ALWAYS use a new gasket at each pipe joint whenever the joint is disassembled. Use new nuts and bolts to hold the joint properly. These two low-cost items will serve to prevent future leaks as the system ages.
- Tighten the supports and hangers. Make certain the rubber hangers are securely attached to their mounts.