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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 809 (Engine Exhaust System) >> Repair Instructions >> Muffler Replacement (6.0L and 8.1L Engines) >> Installation Procedure

Installation Procedure

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  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.
  3. Install the oxygen sensor.
    NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners 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.

    Tighten 

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

    Fig 1: Installing Muffler Oxygen Sensor
    G02119482Courtesy 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. Lower the vehicle.
    Fig 2: Installing Muffler To Catalytic Converter
    G02119483Courtesy of GENERAL MOTORS CORP.
  9. Install the exhaust muffler nuts, until snug.
  10. Tighten the exhaust pipe clamp bolt and muffler nuts.

    Tighten 

    • Tighten the nuts to 40 N.m (30 lb ft).
    • Tighten the clamp to 40 N.m (30 lb ft).
    11. Fig 3: Installing Exhaust Pipe Clamp Bolt And Muffler Nuts
    G02119484Courtesy of GENERAL MOTORS CORP.
  11. If equipped with a 6.0L engine, perform the following:
    • Connect the oxygen sensor electrical connector.
      • Fig 4: Installing Oxygen Sensor Electrical Connector To Frame (6.0L)
      G02119485Courtesy of GENERAL MOTORS CORP.
    • Connect the CPA retainer.
    • Clip the oxygen sensor connector to the frame.
  12. Connect the oxygen sensor electrical connector.
  13. Connect the CPA retainer.
  14. Clip the oxygen sensor connector to the support.
    15. Fig 5: Installing Oxygen Sensor Connector To Support
    G02119486Courtesy of GENERAL MOTORS CORP.
  15. Connect the oxygen sensor electrical connector.
  16. Connect the CPA retainer.
    17. Fig 6: Installing CPA Retainer
    G02119487Courtesy of GENERAL MOTORS CORP.
  17. Clip the oxygen sensor connector to the support.
  18. Connect the oxygen sensor electrical connector.
  19. Connect the CPA retainer.
  20. Clip the oxygen sensor connector to the frame.
    21. Fig 7: Installing Oxygen Sensor Connector To Frame
    G02119488Courtesy of GENERAL MOTORS CORP.
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