Toyota
Jeep Cherokee
 Service Manual
Exhaust system » Removal and installation
Muffler and tailpipe

All original equipment exhaust systems are manufactured with the exhaust tailpipe welded to the muffler.

Service replacement mufflers and exhaust tailpipes are either clamped together or welded together.

Fig. 9 Catalytic Converter to Muffler and Exhaust Pipe Connection
Fig. 9 Catalytic Converter to Muffler and Exhaust Pipe Connection

1 - EXHAUST CLAMP ASSEMBLY
2 - OXYGEN SENSOR
3 - MUFFLER
4 - CATALYTIC CONVERTER
5 - EXHAUST PIPE

WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINE.

CAUTION: When servicing exhaust system components, disconnect the oxygen sensor connector.

Allowing the exhaust system to hang by the oxygen sensor harness will damage the wiring and/or sensor.

REMOVAL

(1) Raise and support the vehicle.

(2) Disconnect front tailpipe hanger from the insulator (Fig. 10).

(3) Remove the front exhaust clamp from the catalytic converter and muffler connection (Fig. 11).

(4) Heat the catalytic converter-to-muffler connection with an oxyacetylene torch until the metal becomes cherry red.

(5) While the metal is still cherry red, remove the exhaust muffler/tailpipe assembly from the catalytic converter.

(6) Slide the muffler/tailpipe assy. rearward and out of the rear exhaust tailpipe mounting bracket (Fig. 11).

Fig. 10 Front Exhaust Tailpipe Hanger
Fig. 10 Front Exhaust Tailpipe Hanger

1 - MUFFLER
2 - INSULATOR
3 - TAILPIPE
4 - FRONT TAILPIPE HANGER

(7) Remove the muffler from the exhaust tailpipe:

  • To remove an original equipment exhaust muffler/ tailpipe combination, cut the exhaust tailpipe close to the muffler. Collapse the part remaining in the muffler and remove.
  •  To remove a service exhaust tailpipe/muffler combination, apply heat until the metal becomes cherry red. Remove the exhaust tailpipe/muffler clamp and twist the exhaust tailpipe out of the muffler.

INSTALLATION

(1) Install the muffler onto the catalytic converter.

Install the clamp and tighten the nut finger tight.

(2) Install the exhaust tailpipe into the rear of the muffler.

(3) Install the exhaust tailpipe/muffler assembly on the rear exhaust tailpipe mounting bracket. Make sure that the exhaust tailpipe has sufficient clearance from the floor pan.

(4) Install front tailpipe hanger into the insulator (Fig. 10).

(5) Align the muffler and tighten the nuts on the muffler-to-catalytic converter clamp to 61 N·m (45 ft.

lbs.) torque (Fig. 11).

(6) Align the tailpipe and install a new clamp at the muffler to tailpipe connection.

(7) Tighten the muffler to tailpipe clamp to 61 N·m (45 ft. lbs.) (8) Lower the vehicle.

Fig. 11 Muffler/Tailpipe Removal and Installation
Fig. 11 Muffler/Tailpipe Removal and Installation

1 - MUFFLER AND TAIL PIPE HANGER
2 - CLAMP
3 - CATALYTIC CONVERTER
4 - MUFFLER AND TAIL PIPE ASSEMBLY
5 - TAIL PIPE
6 - TAIL PIPE HANGER CLAMP

(9) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels.

Adjust the alignment, if needed.

    More about «Removal and installation»:

    Exhaust pipe

    Catalytic converter

    Muffler and tailpipe

    Heat shields

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