Installation Procedure

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2004 Oldsmobile Bravada, 2004 GMC Envoy XUV, 2004 GMC Envoy XL, 2004 GMC Envoy, and 2004 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Removing/Installing Exhaust Hanger From Catalytic Converter Pipe

Courtesy of GENERAL MOTORS CORP.

Install the exhaust hanger to the catalytic converter pipe.
Install the catalytic converter pipe to the vehicle.
Install the transmission mount. Refer to Transmission Mount Replacement (4.2L) or Transmission Mount Replacement (5.3L) in Automatic Transmission-4L60-E/4L65-E.
Install the converter pipe to the muffler.

Fig 2: Exhaust Pipe To Muffler Joint
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to Fastener Notice in Cautions and Notices.

IMPORTANT: The exhaust flange nuts must be tightened evenly to align the joint and prevent exhaust leaks.

Hand thread both nuts evenly until they contact the exhaust flange.
Tighten: Tighten the nuts to 45 N.m (33 lb ft).

IMPORTANT: Do NOT reuse the old exhaust seal. ALWAYS replace the exhaust seal to prevent exhaust leaks.

Fig 3: Removing/Installing Catalytic Converter Pipe From Exhaust Manifold

Courtesy of GENERAL MOTORS CORP.

Install the converter pipe to the exhaust manifold with a NEW exhaust seal.
Hand thread the nuts evenly against the exhaust flange until the pipe is secure.
Tighten: Tighten the nuts to 50 N.m (37 lb ft).
Install the H2OS. Refer to Heated Oxygen Sensor Replacement - Position 2 in Engine Controls - 4.2L.
Lower the vehicle.