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For 1990-2009 cars only

Exhaust System Replacement LP1

Removal Procedure

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

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


    Object Number: 1201222  Size: SH
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Disconnect the left and right bank 2 heated oxygen sensor (HO2S) electrical connectors (bank 1 shown, bank 2 similar).
  3. Remove the HO2S wiring harnesses from the transmission case.

  4. Object Number: 1224063  Size: SH
  5. Remove the exhaust pipe nuts and separate the exhaust system from the catalytic converters.

  6. Object Number: 1559373  Size: SH
  7. Remove the muffler front hanger from the frame hanger rod.

  8. Object Number: 1559372  Size: SH
  9. Remove the tail pipe hangers from the muffler rods.

  10. Object Number: 772383  Size: SH
  11. Remove the floor panel tunnel brace bolts.
  12. Remove the floor panel tunnel brace from the floor panel.

  13. Object Number: 772373  Size: SH
  14. With the aid of an assistant, lower the exhaust system.
  15. Inspect and replace the exhaust system to catalytic converter seals if excessive wear or damage is noticed.

  16. Object Number: 786659  Size: SH
  17. Remove the muffler rear hangers (2) from the muffler(s).
  18. Remove the HO2S from the exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 and Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 .

Installation Procedure


    Object Number: 786659  Size: SH
  1. Install the HO2S to the exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 and Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 .
  2. Install the muffler rear hangers (2) to the muffler(s).
  3. Notice: Refer to Exhaust System Inspection Notice in the Preface section.

    Notice: Refer to Flex Decoupler Notice in the Preface section.


    Object Number: 772373  Size: SH
  4. With the aid of an assistant, raise the exhaust system into position.
  5. Install the exhaust system (muffler) nuts.

  6. Object Number: 1559372  Size: SH
  7. Install the muffler to the muffler rear hangers.

  8. Object Number: 1559373  Size: SH
  9. Install the muffler rear hanger to the hanger rod.
  10. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1224063  Size: SH
  11. Install the exhaust pipe nuts.
  12. Tighten
    Tighten the nuts to 22 N·m (16 lb ft).


    Object Number: 772383  Size: SH
  13. Install the floor panel tunnel brace to the floor panel.
  14. Install the floor panel tunnel brace bolts.
  15. Tighten
    Tighten the floor panel tunnel brace bolts to 25 N·m (18 lb ft).


    Object Number: 1201222  Size: SH
  16. Connect the left and right bank 2 HO2S electrical connectors (bank 1 shown, bank 2 similar).
  17. Install the HO2S wiring harnesses to the transmission case.
  18. Lower the vehicle.

Exhaust System Replacement LY7

Removal Procedure

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

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


    Object Number: 1201222  Size: SH
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Disconnect the left and right bank 2 heated oxygen sensor (HO2S) electrical connectors (bank 1 shown, bank 2 similar).
  3. Remove the HO2S wiring harnesses from the transmission case.

  4. Object Number: 1224063  Size: SH
  5. Remove the exhaust pipe nuts and separate the exhaust system from the catalytic converters.

  6. Object Number: 1559373  Size: SH
  7. Remove the left muffler front hanger from the frame hanger rod.

  8. Object Number: 1559375  Size: SH
  9. Remove the right muffler front hanger from the frame hanger rod.

  10. Object Number: 1559376  Size: SH
  11. Remove the mufflers from the muffler hanger rods.

  12. Object Number: 772383  Size: SH
  13. Remove the floor panel tunnel brace bolts.
  14. Remove the floor panel tunnel brace from the floor panel.

  15. Object Number: 1215598  Size: SH
  16. With the aid of an assistant, lower the exhaust system.
  17. Inspect and replace the exhaust system to catalytic converter seals if excessive wear or damage is noticed.

  18. Object Number: 786659  Size: SH
  19. Remove the muffler rear hangers (2) from the muffler(s).
  20. Remove the HO2S from the exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 and Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 .

Installation Procedure


    Object Number: 786659  Size: SH
  1. Install the HO2S to the exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 and Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 .
  2. Install the muffler rear hangers (2) to the muffler(s).
  3. Notice: Refer to Exhaust System Inspection Notice in the Preface section.

    Notice: Refer to Flex Decoupler Notice in the Preface section.


    Object Number: 1215598  Size: SH
  4. With the aid of an assistant, raise the exhaust system into position.
  5. Install the exhaust system (muffler) nuts.

  6. Object Number: 1559376  Size: SH
  7. Install the mufflers to the muffler rear hangers.

  8. Object Number: 1559375  Size: SH
  9. Install the right muffler front hanger to the frame hanger rod.

  10. Object Number: 1559373  Size: SH
  11. Install the left muffler front hanger to the frame hanger rod.
  12. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1224063  Size: SH
  13. Install the exhaust pipe nuts.
  14. Tighten
    Tighten the nuts to 22 N·m (16 lb ft).


    Object Number: 772383  Size: SH
  15. Install the floor panel tunnel brace to the floor panel.
  16. Install the floor panel tunnel brace bolts.
  17. Tighten
    Tighten the floor panel tunnel brace bolts to 25 N·m (18 lb ft).


    Object Number: 1201222  Size: SH
  18. Connect the left and right bank 2 HO2S electrical connectors (bank 1 shown, bank 2 similar).
  19. Install the HO2S wiring harnesses to the transmission case.
  20. Lower the vehicle.

Exhaust System Replacement LS2

Servicing of the muffler, resonator or pipe requires the replacement of the exhaust system as a complete one-piece unit.

Removal Procedure

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

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


    Object Number: 772383  Size: SH
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Remove the 2 bolts securing the floor panel tunnel brace to the floor panel.
  3. Remove the floor panel tunnel brace from the floor panel.
  4. Suitably support the exhaust system.
  5. Remove the exhaust pipe nuts securing the exhaust pipes to the catalytic converters.

  6. Object Number: 772376  Size: SH
  7. Pry the front exhaust hangers (1) free from the rear suspension hanger rods.

  8. Object Number: 772379  Size: SH
  9. Apply a suitable lubricant to the tail pipe hanger rods in order to ease the removal of the tail pipe hangers (1).
  10. Pry the tail pipe hangers (1) free from the tail pipe hanger rods.

  11. Object Number: 1215598  Size: SH
  12. With the aid of an assistant, lower the exhaust system.
  13. Remove the catalytic converter seals. Do not reuse the seals.

  14. Object Number: 786659  Size: SH
  15. While the exhaust system is on the floor complete the following:
  16. 11.1. Apply a suitable lubricant to the exhaust pipe hanger rods (3) in order to ease the removal of the front exhaust hangers (2).
    11.2. Pull the front exhaust hangers (2) from the exhaust pipe hanger rods.

Installation Procedure


    Object Number: 786659  Size: SH
  1. While the exhaust system is on the floor complete the following:
  2. 1.1. Apply a soapy solution to the following in order to ease the installation of the hangers:
       • The inner diameter of the front exhaust hangers (2)
       • The exhaust pipe hanger rods (3)
       • The inner diameter of the tail pipe hangers
       • The tail pipe hanger rods (1)
    1.2. Press the front exhaust hangers over the exhaust pipe hanger rods.
  3. Place NEW seals on the catalytic converter flanges.
  4. Notice: Refer to Exhaust System Inspection Notice in the Preface section.


    Object Number: 1215598  Size: SH
  5. With the aid of an assistant, raise the exhaust system into position, aligning the exhaust pipe flanges with the studs located in the rear of the catalytic converters.
  6. Finger tighten the exhaust pipe nuts to the catalytic converter studs.

  7. Object Number: 772379  Size: SH
  8. Press the tail pipe hangers (1) over the tail pipe hanger rods.

  9. Object Number: 772376  Size: SH
  10. Press the front exhaust hangers (1) over the rear suspension hanger rods.
  11. Notice: Refer to Fastener Notice in the Preface section.

  12. Tighten the exhaust pipe nuts.
  13. Tighten
    Tighten the nuts to 30 N·m (22 lb ft).


    Object Number: 772383  Size: SH
  14. Position the floor panel tunnel brace to the floor panel.
  15. Install the 2 bolts securing the floor panel tunnel brace to the floor panel.
  16. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  17. Lower the vehicle.