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Home >> Pontiac >> 2001 >> Aztek Base, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 574 (Engine Exhaust System) >> Repair Instructions >> Muffler Replacement >> Installation Procedure

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.
  1. If equipped with 4.3L, 5.0L, and 5.7L engine with 135 inch wheel base and full body style, 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 persons.
  2. Install the muffler assembly hanger pins to the exhaust hanger insulators.
    Fig 1: Installing Muffler Assembly Hanger Pins
    G01699425Courtesy of GENERAL MOTORS CORP.
  3. If equipped with 4.3L, 5.0L, 5.7L, 6.5L, and 8.1L engine with 155 inch wheel base and full body style, 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 persons.
  4. Install the muffler assembly hanger pins to the exhaust hanger insulators.
    Fig 2: Installing Muffler Assembly Hanger Pins
    G01699426Courtesy of GENERAL MOTORS CORP.
  5. Raise the rear axle with a suitable jack.
    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.
  6. Install the lower shock absorber bolt and the lower shock absorber nut to the axle.

    Tighten 

    Tighten the lower shock absorber nut and the lower shock absorber bolt to 80 N.m (59 ft lbs).

  7. Remove the jackstand from the rear axle.
    Fig 3: Installing Lower Shock Absorber Bolt & Nut
    G01699427Courtesy of GENERAL MOTORS CORP.
  8. If equipped with 5.7L, 6.5L, or 8.1L engine and a 139 inch, 159 inch, or 177 inch wheel base with a cutaway body style, install the muffler assembly from the rear of the vehicle by lifting over the rear axle. Due to the weight of the exhaust system it may take 2 persons.
  9. Install the muffler assembly hanger pins to the exhaust hanger insulators.
    Fig 4: Installing Muffler Assembly Hanger Pins
    G01699428Courtesy of GENERAL MOTORS CORP.
  10. Raise the right side of the rear axle with a suitable jack.
  11. Install the lower shock absorber bolt and the lower shock absorber nut to the axle.

    Tighten 

    Tighten the lower shock absorber nut and the lower shock absorber bolt to 80 N.m (59 ft lbs).

    Fig 5: Installing & Tightening Lower Shock Absorber Bolt & Nut
    G01699429Courtesy of GENERAL MOTORS CORP.
  12. Install the right rear spring anchor plate.
  13. Install the spring U-bolts.

    Important:  Tighten the outer U-Bolt nuts and then tighten the inner U-Bolt nuts (1) to 25 N.m (18 ft lbs). Then tighten the U-Bolt nuts (1) in a cross pattern sequence as shown.

  14. Install the U-bolt nuts.

    Tighten 

    • For vehicles below 7300 GVW, tighten the U-bolt nuts to 95 N.m (70 ft lbs).
    • For vehicles above 7300 GVW, tighten the U-bolt nuts to 150 N.m (111 ft lbs).
  15. Install the tire and wheel. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION .
    Fig 6: Installing Right Rear Spring Anchor Plate
    G01699430Courtesy of GENERAL MOTORS CORP.
  16. If equipped with 4.3L, 5.0L, or 5.7L engine with a single catalytic converter pipe, 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 ft lbs).

    Fig 7: Installing Retaining Nuts & New Gasket To Front Of Muffler
    G01699431Courtesy of GENERAL MOTORS CORP.
  17. If equipped with 5.0L or 5.7L engine with dual catalytic converter pipes or an 8.1L engine, install the right catalytic converter in the muffler.
  18. 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 ft lbs).
    • Tighten the catalytic converter to the muffler flange nuts to 48 N.m (35 ft lbs).
    Fig 8: Installing Right Catalytic Converter & Left Catalytic Converter Gasket & Nuts
    G01699432Courtesy of GENERAL MOTORS CORP.
  19. If equipped with 6.5L engine, install a new gasket and the nuts retaining the exhaust pipe to the muffler flange.

    Tighten 

    Tighten the flange nuts to 48 N.m (35 ft lbs).

    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.
  20. Verify the exhaust system for proper clearance and the alignment of all components.
  21. Lower the vehicle.
    Fig 9: Installing Gasket & Nuts Retaining Exhaust Pipe
    G01699433Courtesy of GENERAL MOTORS CORP.
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