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.

If removed, install the oxygen sensors as necessary. Refer to OXYGEN SENSOR .
If equipped with 2 catalytic converter pipes, install the left catalytic converter and gasket to the muffler flange.
Install the nuts for left catalytic converter to muffler.
Do not tighten the flange nuts.
Install the right catalytic converter into the muffler.
Install the right catalytic converter clamp. Do not tighten the clamp.

Fig 1: Installing Right & Left Catalytic Converter
Courtesy of GENERAL MOTORS CORP.
If equipped with a single catalytic converter pipe, install the pipe with a new gasket to the muffler flange.
Do not tighten the flange nuts.

Fig 2: Installing Pipe With New Gasket
Courtesy of GENERAL MOTORS CORP.
Install a new seal and the catalytic converter pipe to the exhaust manifolds.
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 nuts retaining the catalytic converter pipes to the exhaust manifolds.
Tighten
- Tighten the catalytic converter pipe to exhaust manifold nuts to 65 N.m (48 ft lbs).
- Verify that the exhaust system is properly aligned and tighten the right catalytic converter clamp to 54 N.m (40 ft lbs).
- Tighten the catalytic converter to the muffler nuts to 48 N.m (35 ft lbs).
Fig 3: Installing Nuts Retaining Catalytic Converter Pipes
Courtesy of GENERAL MOTORS CORP.
Connect the oxygen sensor (O2S) electrical connection.
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 4: Connecting Oxygen Sensor (O2S) Electrical Connection
Courtesy of GENERAL MOTORS CORP.