Installation Procedure

WARNING: This page is about a different car, the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, and 2002 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.

Install the oxygen sensors as necessary. Refer to OXYGEN SENSOR .
Position the catalytic pipe to the vehicle.
Install the new retaining nuts and gasket to the front of the muffler.
Do not tighten the nuts.

Fig 1: Installing Catalytic Pipe
Courtesy of GENERAL MOTORS CORP.

CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fastener requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Install the new seals, the nuts and the exhaust pipe flange to exhaust manifold.
Tighten
- Tighten the exhaust pipe flange to exhaust manifold nuts to 65 N.m (48 ft lbs).
- Tighten the catalytic converter to muffler retaining nuts to 48 N.m (35 ft lbs).
Fig 2: Installing New Seals, Nuts & Exhaust Pipe Flange
Courtesy of GENERAL MOTORS CORP.
Connect the HO2S electrical connections.
Install the transmission support. Refer to TRANSMISSION SUPPORT .
CAUTION: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials.
Verify the exhaust system for proper clearance and the alignment of all components.
Lower the vehicle.

Fig 3: Connecting HO2S Electrical Connections
Courtesy of GENERAL MOTORS CORP.