LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1390 (Engine Exhaust System) >> Repair Instructions >> Muffler Replacement (6.0L and 8.1L Engines) >> Installation Procedure

Installation Procedure

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 Chevrolet Tahoe, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View of Oxygen Sensor at Muffler
    GM695550Courtesy of GENERAL MOTORS CORP.
  1. If the muffler was replaced reinstall the old oxygen sensor.
  2. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensor.
    NOTE: Refer to FASTENER NOTICE .
  3. Install the oxygen sensor.

    Tighten:  Tighten the oxygen sensor to 42 N.m (31 lb ft).

    4. Fig 2: View of Muffler
    GM665522Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Apply lubricant to the insulators to aid in installation.
  4. Install the insulators to the muffler hangers.
  5. Install a new exhaust manifold pipe gasket.
  6. With the aid of an assistant, slide the muffler forward in order to install the muffler to the catalytic converter.
  7. Install the insulators to the frame hangers.
    8. Fig 3: Identifying Exhaust Muffler Nuts
    GM665520Courtesy of GENERAL MOTORS CORP.
  8. Install the exhaust muffler nuts, until snug.
  9. Tighten the exhaust pipe clamp bolt and muffler nuts.

    Tighten: 

    • Tighten the exhaust muffler nuts to 40 N.m (30 lb ft).
    • Tighten the exhaust pipe clamp to 40 N.m (30 lb ft).

    10. Fig 4: View of Oxygen Sensor & Electrical Connector
    GM694907Courtesy of GENERAL MOTORS CORP.
  10. If equipped with a 6.0L engine, perform the following:
    • Connect the oxygen sensor electrical connector.
    • Connect the CPA retainer.
    • Clip the oxygen sensor connector to the frame.
    11. Fig 5: View of Oxygen Sensor, Electrical Connector, & CPA Retainer
    GM694902Courtesy of GENERAL MOTORS CORP.
  11. Connect the oxygen sensor electrical connector.
  12. Connect the CPA retainer.
  13. Clip the oxygen sensor connector to the support.
    14. Fig 6: Identifying Rear Shock Absorbers Lower Bolts & Nuts
    GM665315Courtesy of GENERAL MOTORS CORP.
  14. Raise the rear axle using the adjustable jack stands.
  15. Install the rear shock absorbers lower bolts and nuts.

    Tighten:  Tighten the lower bolts to 95 N.m (70 lb ft).

  16. Remove the adjustable jack stands from under the rear axle.
    17. Fig 7: View of Rear Axle Vent Hose
    GM695038Courtesy of GENERAL MOTORS CORP.
  17. If equipped with a 10.5 inch ring gear, connect the vent hose swivel clip to the rear brake crossover pipe.
  18. Install the rear axle vent hose to the rear axle, if necessary.
    19. Fig 8: View of Rear Axle Vent Hose
    GM692548Courtesy of GENERAL MOTORS CORP.
  19. If equipped with a 8.6 or 9.5 inch ring gear, connect the vent hose swivel clip to the rear brake crossover pipe.
  20. Install the rear axle vent hose to the rear axle, if necessary.
    21. Fig 9: Identifying Electronic Suspension Rear Position Sensor & Rear Shock
    GM665311Courtesy of GENERAL MOTORS CORP.
  21. If servicing a vehicle equipped with RPO Z55, install the left and right sensor link rods to the sensors. Using J 38185  install the link rods to the ball studs on the sensor levers.
  22. Connect the chassis harness to the following electrical connectors:
    • Electronic suspension rear position sensor (1)
    • Rear shock (2)
  23. Install the spare tire.
    24. Fig 10: View of Oil Pan Skid Plate
    GM339429Courtesy of GENERAL MOTORS CORP.
  24. Install the oil pan skid plate and bolts, if necessary.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

  25. Install the rear tires and wheels. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION .
scientia non olet · About LEMON Manuals