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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1028 (Engine Exhaust System) >> Repair Instructions >> Muffler Replacement (6.0L, 6.6L, and 8.1L Engines) >> Installation Procedure

Installation Procedure

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  1. If equipped with a 6.0L or 8.1L engine, and the muffler was replaced re-install the old oxygen sensor.
    Fig 1: Oxygen Sensor (6.0L and 8.1L Engines)
    GM695550Courtesy of GENERAL MOTORS CORP.
  2. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensor.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the oxygen sensor.

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

    4. Fig 2: Exhaust Insulators (6.6L Engine)
    GM694340Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Apply lubricant to the insulators to aid in installation.
  4. If equipped with a 6.6L engine, install the insulators to the muffler hangers.
  5. Install a new exhaust muffler gasket.
  6. With the aid of an assistant, slide the muffler forward in order to install the muffler to the exhaust muffler pipe.
  7. Install the insulators to the frame hangers.
    8. Fig 3: Exhaust Muffler (6.0L and 8.1L Engines)
    GM858603Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Apply lubricant to the insulators to aid in installation.
  8. If equipped with a 6.0L or 8.1L engine, install the insulators to the muffler hangers.
  9. Install a new exhaust manifold pipe gasket.
  10. With the aid of an assistant, slide the muffler forward in order to install the muffler to the catalytic converter.
  11. Install the insulators to the frame hangers.
    12. Fig 4: Exhaust Muffler Nuts (6.0L, 6.6L, and 8.1L Engines)
    GM694338Courtesy of GENERAL MOTORS CORP.
  12. If equipped with a 6.6L engine, install the exhaust muffler nuts.

    Tighten:  Tighten the nuts to 40 N.m (30 lb ft).

    13. Fig 5: Exhaust Muffler Nuts (6.0L and 8.1L Engines)
    GM858609Courtesy of GENERAL MOTORS CORP.
  13. If equipped with a 6.0L or 8.1L engine, position the NEW band clamp on the intermediate exhaust pipe, using the alignment mark created previously. The band clamp bolt must NOT be positioned below the exhaust pipe.
  14. Install the exhaust muffler nuts.
  15. Tighten the exhaust pipe clamp bolt.

    Tighten: 

    • Tighten the nuts to 40 N.m (30 lb ft).
    • Tighten the clamp to 44 N.m (33 lb ft).

  16. Raise the rear axle using the adjustable jack stands, if necessary.
  17. Install the rear shock absorbers lower bolts and nuts, if necessary.

    Tighten:  Tighten the bolts to 95 N.m (70 lb ft).

    Fig 6: Rear Shock Absorber Bolts And Nuts (6.0L, 6.6L, and 8.1L Engines)
    GM665315Courtesy of GENERAL MOTORS CORP.
    18. Fig 7: Rear Axle Vent Hose (10.5 Inch Ring Gear)
    GM695038Courtesy of GENERAL MOTORS CORP.
  18. If equipped with a 10.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  19. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
    20. Fig 8: Rear Axle Vent Hose (8.6 or 9.5 Inch Ring Gear)
    GM692548Courtesy of GENERAL MOTORS CORP.
  20. If equipped with a 8.6 or 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  21. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  22. Remove the adjustable jack stands from under the rear axle, if necessary.
  23. Install the spare tire, if necessary.
  24. Lower the vehicle.
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