GM 25887916
Muffler W/Tpipe

First you must lift off and support the automobile properly before lifting. It is important not to reuse any components that have been oxidized, damaged, or in any way compromised. For the vehicle with the ll8 engine, purchase the resonator and Tail Pipe because they are likely to be replaced together, typically fixed using a clamp. Check the exhaust system parts for reusability. Pull out and remove the nuts on the left and right sides that hold the support that the Muffler is connected to the Catalytic Converter pipe. Isolate the Muffler and tailpipe assembly from the hanger insulators and lower the assembly. Support the exhaust system then cut the Exhaust Pipe at the line designated and take away the Muffler from the pipe in the tail. For installation, connect the new Muffler to the tailpipe and fasten it to hanger insulators. Mount the Muffler to the Catalytic Converter and tighten the nuts to 45 nm (33 ft. Lbs.). Loosely put in the clamp in order to hold the Muffler onto the tailpipe, align the tailpipe properly and tighten the clamp nuts with a torque of 50 nm (37 ft. Lbs). Lastly, check for leaks in the exhaust system and for underbody contact, replace the frame brace and lower the vehicle.

The Muffler replacement process starts with frame brace and spare tire followed by removing the rear axle Tie Rod and rear axle brace. The process continues by removing shock absorber lower mounting bolts before setting them aside. Follow this step by removing the right rear coil spring when present. Remove the Muffler to Catalytic Converter nuts from a 4.2l engine. The Muffler to Catalytic Converter nuts require removal according to the engine type if you have a 5.3l or 6.0l vehicle. You need assistance to detach the Muffler's exhaust insulators (1, 3, and 4) from the hangers before you remove the entire Muffler assembly from the vehicle. Position the Muffler assembly back onto the vehicle with help before you reattach exhaust insulators (1, 3, and 4) onto the Muffler hangers. When working with 5.3l or 6.0l engines install the Muffler to Catalytic Converter nuts while torquing them to 45 n.m (33 lb ft). When installing the Catalytic Converter to Muffler nuts on a 4.2l engine maintain a torque setting at 45 n.m (33 lb ft) before continuing. Install the right rear coil spring when present and position the shock absorbers before installing the lower mounting bolts. To complete the installation you must reinstall the rear axle brace together with the rear axle Tie Rod and spare tire before remounting the frame brace.

Proper vehicle elevation through support becomes essential before beginning Muffler replacement. All exhausted system parts requiring replacement must be new because damaged or corroded components are unfit for reuse. Vehicle owners must order both the resonator and tailpipe for vehicles using the ll8 engine system although these components may be clamped together. Start by evaluating exhaust system components for reuse and detach the frame brace. Begin by removing the nuts fixing the Muffler to the catalytic converter pipe then extract the Muffler from the tailpipe assembly at its hanger insulators. Drop the Muffler-tailpipe assembly before cutting through the Exhaust Pipe while supported at the exhaust system. Remove the Muffler from tailpipe following this procedure. During installation position the new Muffler onto the tailpipe pipe and lock it into position by connecting it to the hanger insulators while strictly following the fastener recommendation. Fasten the Muffler to the catalytic converter through nuts that require torque of 45 n.m (33 lb ft). Attach the clamp loosely to secure the Muffler onto the tailpipe followed by tailpipe alignment before tightening clamp nuts to 50 n.m (37 lb ft). The final steps require leak testing of the exhaust system and installing the frame brace and lowering the vehicle back to its original position.

Next, detach the shock absorber lower mounting bolts and set them aside, then remove the right rear coil spring if equipped.