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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1783 (Engine Exhaust System) >> Repair Instructions >> Muffler Replacement (6.0L, 6.6L, and 8.1L Engines) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
CAUTION: Refer to PROTECTIVE GOGGLES & GLOVE CAUTION in Cautions and Notices.
  1. Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  2. Remove the spare tire, if necessary.
  3. Install adjustable jack stands under the rear axle, if necessary.
  4. If equipped with a 8.6 or 9.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary.
  5. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.
    Fig 1: Removing Rear Axle Vent Hose (6.0L, 6.6L & 8.1L w/8.6" Or 9.5" Ring Gear)
    G02133625Courtesy of GENERAL MOTORS CORP.
  6. If equipped with a 10.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary.
  7. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.
    Fig 2: Removing Rear Axle Vent Hose (6.0L, 6.6L & 8.1L w/10.5" Ring Gear)
    G02133626Courtesy of GENERAL MOTORS CORP.
  8. Remove the rear shock absorbers lower bolts and nuts, if necessary.
  9. Lower the rear axle using the adjustable jack stands, if necessary.
    Fig 3: Removing Rear Shock Absorbers Lower Bolts & Nuts (6.0L, 6.6L & 8.1L)
    G02133627Courtesy of GENERAL MOTORS CORP.
  10. If equipped with a 6.0L or 8.1L engine, perform the following:
    • Unclip the oxygen sensor connector from the frame.
    • Disconnect the connector position assurance (CPA) retainer.
    • Disconnect the oxygen sensor electrical connector.
    Fig 4: Disconnecting Oxygen Sensor Electrical Connector At Frame (6.0L & 8.1L)
    G02133628Courtesy of GENERAL MOTORS CORP.
  11. If equipped with a 6.0L or 8.1L engine, perform the following:
    • Unclip the oxygen sensor connector from the support.
    • Disconnect the CPA retainer.
    • Disconnect the oxygen sensor electrical connector.
    Fig 5: Disconnecting Oxygen Sensor Electrical Connector At Support (6.0L & 8.1L)
    G02133629Courtesy of GENERAL MOTORS CORP.
  12. If equipped with a 6.0L or 8.1L engine, perform the following:
    • Unclip the oxygen sensor connector from the support.
    • Disconnect the CPA retainer.
    • Disconnect the oxygen sensor electrical connector.
    Fig 6: Disconnecting Oxygen Sensor Electrical Connector At Support (6.0L & 8.1L)
    G02133630Courtesy of GENERAL MOTORS CORP.
  13. If equipped with a 6.0L engine, perform the following:
    • Unclip the oxygen sensor connector from the frame.
    • Disconnect the CPA retainer.
    • Disconnect the oxygen sensor electrical connector.
    Fig 7: Disconnecting Oxygen Sensor Electrical Connector At Frame (6.0L)
    G02133631Courtesy of GENERAL MOTORS CORP.
  14. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler nuts.
  15. Loosen the exhaust pipe clamp.
  16. With the aid of an assistant, support the exhaust muffler.
    Fig 8: Removing Exhaust Muffler Nuts (6.0L & 8.1L)
    G02133632Courtesy of GENERAL MOTORS CORP.
  17. If equipped with a 6.6L engine, remove the exhaust muffler nuts.
  18. With the aid of an assistant, support the exhaust muffler.
    Fig 9: Removing Exhaust Muffler Nuts (6.6L)
    G02133633Courtesy of GENERAL MOTORS CORP.
  19. If equipped with a 6.0L or 8.1L engine, remove the insulators from the frame hangers.
  20. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the catalytic converter.
  21. Remove the insulators from the muffler hangers.
  22. Remove the exhaust manifold pipe gasket, if necessary.
    Fig 10: Removing Exhaust Muffler (6.0L & 8.1L)
    G02133634Courtesy of GENERAL MOTORS CORP.
  23. If equipped with a 6.6L engine, remove the insulators from the frame hangers.
  24. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the exhaust muffler pipe.
  25. Remove the exhaust muffler gasket, if necessary.
  26. Remove the insulators from the muffler hangers.
    Fig 11: Removing Exhaust Muffler (6.6L)
    G02133635Courtesy of GENERAL MOTORS CORP.
  27. If equipped with a 6.0L or 8.1L engine, remove the oxygen sensor if the muffler is being replaced.
    Fig 12: Removing Oxygen Sensor (6.0L & 8.1L)
    G02133636Courtesy of GENERAL MOTORS CORP.
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