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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1494 (Engine Exhaust System) >> Repair Instructions >> Muffler Replacement (6.0L, 6.6L, and 8.1L Engines) >> Installation Procedure

Installation Procedure

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NOTE: Refer to EXHAUST SYSTEM INSPECTION NOTICE in Cautions and Notices.
  1. If equipped with a 6.0L or 8.1L engine, and the muffler was replaced re-install the old oxygen sensor.
  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).

    Fig 1: Installing Oxygen Sensor (6.0L & 8.1L)
    G02133637Courtesy 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.
    Fig 2: Installing Exhaust Muffler (6.6L)
    G02133638Courtesy 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.
    Fig 3: Installing Exhaust Muffler (6.0L & 8.1L)
    G02133639Courtesy 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).

    Fig 4: Installing Exhaust Muffler Nuts (6.6L)
    G02133640Courtesy of GENERAL MOTORS CORP.
  13. If equipped with a 6.0L or 8.1L engine, install the exhaust muffler nuts.
  14. Tighten the exhaust pipe clamp bolt.

    Tighten 

    • Tighten the nuts to 40 N.m (30 lb ft).
    • Tighten the clamp to 40 N.m (30 lb ft).
    Fig 5: Installing Exhaust Muffler Nuts (6.0L & 8.1L)
    G02133641Courtesy of GENERAL MOTORS CORP.
  15. If equipped with a 6.0L engine, perform the following:
    • Connect the oxygen sensor electrical connector.
    • Connect the CPA retainer.
    • Clip the oxygen sensor connector to the frame.
    Fig 6: Connecting Oxygen Sensor Electrical Connector At Frame (6.0L)
    G02133642Courtesy of GENERAL MOTORS CORP.
  16. If equipped with a 6.0L or 8.1L engine, perform the following:
    • Connect the oxygen sensor electrical connector.
    • Connect the CPA retainer.
    • Clip the oxygen sensor connector to the support.
    Fig 7: Connecting Oxygen Sensor Electrical Connector At Support (6.0L & 8.1L)
    G02133643Courtesy of GENERAL MOTORS CORP.
  17. If equipped with a 6.0L or 8.1L engine, perform the following:
    • Connect the oxygen sensor electrical connector.
    • Connect the CPA retainer.
    • Clip the oxygen sensor connector to the support.
    Fig 8: Connecting Oxygen Sensor Electrical Connector At Support (6.0L & 8.1L)
    G02133644Courtesy of GENERAL MOTORS CORP.
  18. If equipped with a 6.0L or 8.1L engine, perform the following:
    • Connect the oxygen sensor electrical connector.
    • Connect the CPA retainer.
    • Clip the oxygen sensor connector to the frame.
    Fig 9: Connecting Oxygen Sensor Electrical Connector At Frame (6.0L & 8.1L)
    G02133645Courtesy of GENERAL MOTORS CORP.
  19. Raise the rear axle using the adjustable jack stands, if necessary.
  20. Install the rear shock absorbers lower bolts and nuts, if necessary.

    Tighten 

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

    Fig 10: Installing Rear Shock Absorbers Lower Bolts & Nuts (6.0L, 6.6L & 8.1L)
    G02133646Courtesy of GENERAL MOTORS CORP.
  21. If equipped with a 10.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  22. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
    Fig 11: Installing Rear Axle Vent Hose (6.0L, 6.6L & 8.1L w/10.5" Ring Gear)
    G02133647Courtesy of GENERAL MOTORS CORP.
  23. If equipped with a 8.6 or 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  24. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  25. Remove the adjustable jack stands from under the rear axle, if necessary.
  26. Install the spare tire, if necessary.
  27. Lower the vehicle.
    Fig 12: Installing Rear Axle Vent Hose (6.0L, 6.6L & 8.1L w/8.6" Or 9.5" Ring Gear)
    G02133648Courtesy of GENERAL MOTORS CORP.
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