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Home >> Chevrolet >> 2004 >> Chevy Express H1500, Van Cargo >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Muffler Replacement >> Installation Procedure

Installation Procedure

    Fig 1: View Of Muffler Assembly Hanger Pins
    GM1202614Courtesy of GENERAL MOTORS CORP.
  1. Install the muffler assembly from the front of the vehicle by lifting over the rear axle. Due to the weight of the exhaust system it may take 2 people.
  2. Install the muffler assembly hanger pins to the exhaust hanger insulators.
    3. Fig 2: View Of Catalytic Converter Pipe At Muffler (4.3L)
    GM1202609Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. If equipped with a 4.3L engine, install the retaining nuts and new gasket to the front of the muffler.

    Tighten:  Tighten the catalytic converter to muffler retaining nuts to 48 N.m (35 lb ft).

    4. Fig 3: View Of Exhaust Pipe & Catalytic Converter Pipe
    GM1202601Courtesy of GENERAL MOTORS CORP.
  4. If equipped with a 4.8L/4.3L/6.0L engine, install the right catalytic converter in the muffler.

    Tighten:  Tighten the clamp nut to 54 N.m (40 lb ft).

  5. Install a new gasket and the nuts retaining the left catalytic converter to the muffler flange.

    Tighten: 

    • Verify that the exhaust system is properly aligned and tighten the right catalytic converter clamp to 54 N.m (40 lb ft).
    • Tighten the catalytic converter to the muffler flange nuts to 48 N.m (35 lb ft).

  6. Lower the vehicle.
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