Home ReviewsRefund
Home/Chevrolet/Cab & Chassis Silverado 3500/Chevrolet Cab & Chassis Silverado 3500 (2003-2012)/Repair manual/Exhaust/Engine Exhaust System
Contents Section: Exhaust All sections

Engine Exhaust System Chevrolet Cab & Chassis Silverado 3500

Exhaust 1 illustration ~7853 words

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
Catalytic Converter Coupling Nut45 N.m33 lb ft
Exhaust Gas Recirculation (EGR) Cooler Tube Nut (6.6L)30 N.m20 lb ft
Exhaust Hanger Bracket Bolt12 N.m106 lb in
Exhaust Heat Shield Bolt (Body Panel)9 N.m80 lb in
Exhaust Heat Shield Nut (Body Panel)9 N.m80 lb in
Exhaust Manifold Bolts (4.8L, 5.3L, and 6.0L)
First Pass15 N.m11 lb ft
Final Pass25 N.m18 lb ft
Exhaust Manifold Bolt/Nut (6.6L)34 N.m25 lb ft
Exhaust Manifold Bolt/Stud (4.3L)30 N.m22 lb ft
Exhaust Manifold Center Bolt (8.1L)35 N.m26 lb ft
Exhaust Manifold Heat Shield Bolt (4.3L, 4.8L, 5.3L, and 6.0L)9 N.m80 lb in
Exhaust Manifold Heat Shield Bolt (6.6L)8 N.m71 lb in
Exhaust Manifold Heat Shield Bolt/Nut (8.1L)25 N.m18 lb ft
Exhaust Manifold Nut (8.1L)16 N.m12 lb ft
Exhaust Manifold Pipe Nut50 N.m37 lb ft
Exhaust Muffler Hanger Nut50 N.m39 lb ft
Exhaust Muffler Nut40 N.m30 lb ft
Exhaust Outlet Pipe Clamp (6.6L)15 N.m11 lb ft
Exhaust Outlet to Right Exhaust Pipe Bracket Bolt (6.6L)34 N.m25 lb ft
Exhaust Pipe Clamp44 N.m33 lb ft
Exhaust Pipe Hanger Bracket Bolt12 N.m106 lb in
Exhaust Pipe Hanger Bracket Bolt (4L60-E)17 N.m13 lb ft
Exhaust Pipe Heat Shield Bolt (6.6L)8 N.m71 lb in
Exhaust Pipe to Manifold Bolt (6.6L)53 N.m39 lb ft
Exhaust Pipe to Turbocharger Bolt (6.6L)53 N.m39 lb ft
Hood Hinge Bolt25 N.m18 lb ft
Intake Manifold Cover Clamp (6.6L)6 N.m53 lb in
Oil Level Indicator Tube Bracket Bolt (6.6L)21 N.m15 lb ft
Outlet Duct Clamp6 N.m53 lb in
Oxygen Sensor42 N.m31 lb ft
Rear Shock Absorber Lower Bolt95 N.m70 lb ft
Spark Plug (4.3L)15 N.m11 lb ft
Spark Plug Wire Retainer Bolt (4.3L)12 N.m106 lb in
Transmission Bolt100 N.m74 lb ft
Transmission Fluid Fill Tube Nut (6.6L)18 N.m13 lb ft
Transmission Mount to Support Nut40 N.m30 lb ft
Transmission Support Crossmember Bolt95 N.m70 lb ft
Turbocharger Exhaust Pipe Bolt/Nut (6.6L)53 N.m39 lb ft
Turbocharger Exhaust Pipe Heat Shield Bolt (6.6L)8 N.m71 lb in
Turbocharger Heat Shield Bolt (6.6L)9 N.m80 lb in

Fastener Tightening Specifications

Diagnostic Starting Point - Engine Exhaust

Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the information will help you determine the correct symptom diagnostic procedure when a malfunction exists. It will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Engine Exhaust in order to identify the correct procedure for diagnosing the system.

Symptoms - Engine Exhaust

  1. Review the Exhaust System Description and Operation in order to familiarize yourself with the system functions. Refer to «Exhaust System Description»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system__exhaust-system-description) .
  2. All diagnostics on a vehicle should follow a logical process. Strategy Based Diagnostics is a uniform approach for repairing all systems. The diagnostic flow is the place to start when repairs are necessary and may always be used in order to resolve a system problem. For a detailed explanation, refer to «Strategy Based Diagnosis»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/oem-general-information/#vehicle-diagnostic-information__strategy-based-diagnosis) .

Visual/Physical Inspection

  1. Inspect for aftermarket or non-OEM devices such as, but not including; tailpipe extensions, headers, and exhaust cutouts. This could affect the operation and proper performance of the exhaust system.
  2. Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM, engine temperature, engine load, and frequency of concern.
  3. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause any symptom.

Intermittent

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating as designed.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

  1. Loss of power Refer to «Restricted Exhaust»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  2. Poor acceleration Refer to «Restricted Exhaust»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  3. Poor fuel economy Refer to «Restricted Exhaust»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  4. Excessive smoke (diesel) Refer to «Restricted Exhaust»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  5. Exhaust hissing noise Refer to «Exhaust Leakage»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system__exhaust-leakage) .
  6. Exhaust popping noise Refer to «Exhaust Leakage»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system__exhaust-leakage) .
  7. Exhaust rattle noise Refer to «Exhaust Noise»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system__exhaust-noise) .
  8. Loud exhaust noise Refer to «Exhaust Noise»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system__exhaust-noise) .
  9. Exhaust buzz, groan, hum noise Refer to «Exhaust Noise»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system__exhaust-noise) .

Diagnostic Aids

CAUTIONWhile engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

If the vehicle is equipped with a 6.6 L diesel engine do not perform this diagnostic. The exhaust system does not have a location for installing the J 35314-A . See Special Tools . Instead remove the suspect component, operate the vehicle, verify for improved performance. If performance is improved then replace the faulty component.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

  1. 4: The exhaust system has very low back pressure under normal conditions. If the exhaust system is restricted, a significant increase in the exhaust pressure is noticed on the J 35314-A Removing the AIR check valve or HO2S sensor may set a DTC. When finishing this diagnostic table, be sure to clear all codes. See «Special Tools»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system__special-tools) .
  2. 5: This step will isolate the catalytic converter from the remainder of the exhaust system.
  3. 8: Confirming that the condition has been fixed is essential. If the symptom still exists and the vehicle has a dual exhaust system, proceed to Step 2 and repeat diagnostic procedure on the opposite exhaust pipe.
StepActionValue(s)YesNo
1Did you verify the customers complaint?Go to Step 2
2Did you review the exhaust symptoms diagnostic information and perform the necessary inspections?Go to Step 3Go to Symptoms - Engine Exhaust
3Is the vehicle equipped with a 6.6L diesel engine?Go to Diagnostic AidsGo to Step 4
4Remove the AIR check valve or the heated oxygen sensor (HO2S) that is in front of and closest to the catalytic converter. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 for the 4.3L engine, Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 for the 4.8L, 5.3L, and 6.0L engine, Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 for the 8.1L engine. Install the J 35314-A Exhaust Back Pressure Gage in place of the AIR check valve or HO2S sensor. See Special Tools . Start the engine. Increase and monitor the engine speed at 2,000 RPM. Observe the exhaust system back pressure reading on the gage. Does the reading exceed the specified value?20 kPa (3 psi) If equipped with a 4.8L, 5.3L, or 6.0L - 3.4 kPa (0.5 psi)Go to Step 5Go to Step 8
5Turn the engine off and place the ignition in the lock position. Remove the J 35314-A . See Special Tools . Re-install the AIR check valve/HO2S sensor. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 for the 4.3L engine, Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 for the 4.8L, 5.3L, and 6.0L engine, Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 for the 8.1L engine. Remove the post-catalyst HO2S sensor. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for the 4.3L engine, Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for the 4.8L, 5.3L, and 6.0L engine, Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for the 8.1L engine. Install the J 35314-A in place of the post HO2S sensor. See Special Tools . Start the engine. Increase and monitor the engine speed at 2,000 RPM. Observe the exhaust system back pressure reading on the gage. Does the reading exceed the specified value?20 kPa (3 psi) If equipped with a 4.8L, 5.3L, or 6.0L - 3.4 kPa (0.5 psi)Go to Step 6Go to Step 7
6Inspect the exhaust system for the following conditions: Damage in the exhaust pipe Debris in the exhaust pipe Muffler or resonator internal failure Two-layer exhaust pipe separation Did you find and correct the condition?Go to Step 8
7Replace the catalytic converter. Refer to Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines) or Catalytic Converter Replacement (6.0L and 8.1L Engines) or Catalytic Converter Replacement (6.6L Engine) . Did you find and correct the condition?Go to Step 8
8Remove the J 35314-A . See Special Tools . Reinstall the AIR check valve or the HO2S sensor. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for the 4.3L engine, Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for the 4.8L, 5.3L, and 6.0L engine, Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for the 8.1L engine. Clear any codes. Road test the vehicle in order to verify the repair. Did you correct the condition?System OKGo to Step 2

Restricted Exhaust

Exhaust Leakage

ProblemAction
CAUTION: While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system. DEFINITION: An exhaust leak may show stains at the area of the leak. The leak may be felt by holding a hand close to the suspected areas or using a smoke pencil. The leak may make a popping or hissing noise.Refer to Symptoms - Engine Exhaust prior to beginning this table.
Misaligned or improperly installed exhaust system components.Align and tighten the components to the specifications. Refer to Fastener Tightening Specifications . Ensure the exhaust hangers are in the proper locations and not loose. Refer to Exhaust System Insulator, Hanger, Bracket Replacement (6.6L Engine with RPO YF2) .
Exhaust leaks at the following connections: Exhaust manifold to pipe Flanges Pipe clampsTighten the components to the specifications. Refer to Fastener Tightening Specifications .
Seals or gaskets leaking. Exhaust manifold to cylinder head Exhaust pipes to exhaust manifold Catalytic converter connection EGR connections AIR connections to the exhaust manifold or cylinder headReplace the leaking seal or gasket. Refer to the affected components procedure for service.
Irregularities at the mating surfaces on the flange connections.Repair as required or replace the affected component. Refer to the affected components procedure for service.
Exhaust manifold cracked or broken.Replace the exhaust manifold Refer to Exhaust Manifold Replacement - Left Side (4.3L Engine) or Exhaust Manifold Replacement - Left Side (4.8L, 5.3L, and 6.0L Engine) or Exhaust Manifold Replacement - Left Side (6.6L Engine) or Exhaust Manifold Replacement - Left Side (8.1L Engine) or Exhaust Manifold Replacement - Right Side (4.3L Engine) or Exhaust Manifold Replacement - Right Side (4.8L, 5.3L, and 6.0L Engines) or Exhaust Manifold Replacement - Right Side (6.6L Engine) or Exhaust Manifold Replacement - Right Side (8.1L Engine) .
Exhaust system component connection welds leaking.Replace the leaking component. Refer to the affected component's procedure for service.
Muffler or resonator (if equipped) damaged or leaking at the seams.Replace the affected muffler or resonator. Refer to one of the following procedures: Muffler Replacement (4.3L, 4.8L, and 5.3L Engines) or Muffler Replacement (6.0L, 6.6L, and 8.1L Engines) Resonator replacement
CAUTION
While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

Exhaust Leakage

Exhaust Noise

ConditionAction
CAUTION: While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system. DEFINITION: An audible or physical noise due to a faulty component or damaged components causing a loose or misaligned exhaust system resulting in a rattle or vibration noise (buzz, groan, hum).Refer to Symptoms - Engine Exhaust prior to beginning this table.
Popping or hissing noiseExhaust leak. Refer to Exhaust Leakage .
Loud exhaustCompare to a known good vehicle. Inspect for a damaged or failed muffler or resonator. Replace the faulty muffler. Refer to Muffler Replacement (4.3L, 4.8L, and 5.3L Engines) or Muffler Replacement (6.0L, 6.6L, and 8.1L Engines) .
External rattle or vibration noiseInspect for a bent or loose hanger, loose heat shield, or loose clamp. Inspect for a exhaust pipe causing interference. Repair or replace the affected component. Refer to the affected component's service procedure.
Internal rattleTest the components by tapping with a rubber mallet to confirm a rattle. Replace the faulty catalytic converter, or muffler. Refer to one of the following procedures: Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines) Catalytic Converter Replacement (6.0L and 8.1L Engines) Catalytic Converter Replacement (6.6L Engine) Muffler Replacement (4.3L, 4.8L, and 5.3L Engines) Muffler Replacement (6.0L, 6.6L, and 8.1L Engines)
CAUTION
While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

Exhaust Noise

Removal Procedure

  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the exhaust manifold pipe nuts.
  3. Lower the vehicle.
  4. Disconnect the spark plug wires from the spark plugs.
  5. Remove the spark plug wire retainer bolts.
  6. Position the wire harness on top of the engine.
  7. Remove the spark plugs.
  8. Disconnect the engine coolant temperature (ECT) sensor electrical connector (5).
  9. Remove the exhaust manifold and spark plug wire shields bolts/stud.
  10. Remove the exhaust manifold and plug wire shields.
  11. Remove and discard the exhaust manifold gaskets.
  12. Remove the exhaust manifold heat shield bolts and shield, if required.
  13. Clean all gasket mating surfaces.

Installation Procedure

  1. Install the exhaust manifold heat shield and bolts, if required. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  2. Install NEW exhaust manifold gaskets to the exhaust manifold.
  3. Ensure that the exhaust manifold bolts/stud, and plug wire shields are held in place by the tabs on the exhaust manifold gaskets.
  4. Install the exhaust manifold and plug wire shields.
  5. If reusing the old fasteners, apply threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts/stud.
  6. Tighten the exhaust manifold bolts/stud. Tighten: Tighten the bolts/stud to 30 N.m (22 lb ft).
  7. Connect the ECT sensor electrical connector (5).
  8. Install the spark plugs. Tighten: Tighten the plugs to 15 N.m (11 lb ft).
  9. Position the wire harness to the engine.
  10. Install the spark plug wire retainer bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  11. Connect the spark plug wires to the spark plugs.
  12. Raise the vehicle.
  13. Install the exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  14. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the exhaust manifold pipe nuts.
  3. Lower the vehicle.
  4. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-and-60l-introduction-2-of-2) .
  5. Remove the exhaust manifold bolts, manifold, and gasket.
  6. Discard the gasket.
  7. Remove the heat shield bolts (3), and shield (2) from the exhaust manifold (1), if necessary.
  8. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-48l-53l-and-60l-4-of-4__exhaust-manifold-cleaning-and-inspection) .
  1. Install the heat shield (2), and bolts (3) to the exhaust manifold (1), if necessary. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts.
  3. Install the exhaust manifold, NEW gasket and bolts. Tighten: Tighten the bolts a first pass to 15 N.m (11 lb ft). Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the bolts a final pass to 25 N.m (18 lb ft). Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
  4. Using a flat-punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.
  5. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-and-60l-introduction-2-of-2) .
  6. Raise the vehicle.
  7. Install the exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  8. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the exhaust pipe heat shield bolts.
  3. Reposition the heat shield to the side in order to access the exhaust pipe to exhaust manifold bolts.
  4. Lower the vehicle in order to work through the front wheelhouse opening.
  5. Remove the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  6. Remove the charged air cooler outlet duct. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Driver Side)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Charged Air Cooler Hoses/Pipes Replacement (Passenger Side)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
  7. Remove the exhaust pipe to exhaust manifold bolts (1, 2, and 3).
  8. Remove the exhaust manifold heat shield bolts.
  9. Remove the exhaust manifold heat shield.
  10. Remove the exhaust manifold bolts and nuts in the proper sequence.
  11. Remove the exhaust manifold.
  12. Remove and discard the exhaust manifold gasket.
  13. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5__exhaust-manifold-cleaning-and-inspection) .
  1. Install the exhaust manifold with gasket.
  2. Install the exhaust manifold bolts/nuts.
  3. Use the sequence shown to properly tighten the exhaust manifold bolts. Tighten: Tighten the bolts/nut to 38 N.m (28 lb ft).
  4. Install the exhaust manifold heat shield.
  5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  6. Install the exhaust pipe gasket. Align the tab on the gasket to face outward.
  7. Install the exhaust pipe and the bolts (1, 2, and 3) to the exhaust manifold. Tighten: Tighten the bolts to 53 N.m (39 lb ft).
  8. Raise the vehicle.
  9. Install the exhaust pipe heat shield bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  10. Install the charged air cooler outlet duct. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Driver Side)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) or «Charged Air Cooler Hoses/Pipes Replacement (Passenger Side)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
  11. Install the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  12. Lower the vehicle.
  1. Remove the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  2. Remove the spark plug wires from the spark plugs and ignition coils.
  3. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-and-60l-introduction-2-of-2) .
  4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  5. Remove the exhaust manifold heat shield bolts and nuts.
  6. Remove the left exhaust manifold heat shield.
  7. Lower the vehicle.
  8. Remove the exhaust manifold bolt and nuts.
  9. Remove the exhaust manifold.
  10. Remove and discard the exhaust manifold gasket.
  11. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-81l__exhaust-manifold-cleaning-and-inspection) .
  1. Install a NEW exhaust manifold gasket.
  2. Install the exhaust manifold. NOTE: Refer to «Fastener Notice»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/oem-general-information/#warnings-and-cautions__fastener-notice) .
  3. Install the exhaust manifold bolt and nuts. Tighten: Tighten the bolt to 35 N.m (26 lb ft). Tighten the nuts to 16 N.m (12 lb ft).
  4. Raise the vehicle.
  5. Install the exhaust manifold heat shield.
  6. Install the exhaust manifold heat shield bolts and nuts. Tighten: Tighten the bolts and nuts to 25 N.m (18 lb ft).
  7. Lower the vehicle.
  8. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-and-60l-introduction-2-of-2) .
  9. Install the spark plug wires to the spark plugs and ignition coils.
  10. Install the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the right exhaust manifold pipe nuts.
  3. Lower the vehicle.
  4. Loosen the air cleaner outlet duct clamp at the mass airflow (MAF)/intake air temperature (IAT) sensor.
  5. Remove the positive crankcase ventilation (PCV) hose.
  6. Remove the air cleaner adapter nut.
  7. In order to remove the air cleaner outlet duct, pivot the duct upward until the hinge clip releases from the lip on the throttle body.
  8. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-277938-S42202594572008012100000) .
  9. Disconnect the spark plug wires from the spark plugs.
  10. Remove the spark plug wire retainer bolt.
  11. Reposition the wire retainer to the top of the engine.
  12. Remove the spark plugs.
  13. Remove the exhaust manifold and spark plug heat shield bolts.
  14. Remove the exhaust manifold and spark plug heat shields.
  15. Remove and discard the exhaust manifold gaskets.
  16. Remove the exhaust manifold heat shield, if required.
  17. Clean all gasket mating surfaces.
  1. Install the exhaust manifold heat shield, if required.
  2. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  3. Install NEW exhaust manifold gaskets to the exhaust manifold.
  4. Ensure that the exhaust manifold bolts, and plug wire shields are held in place by the tabs on the exhaust manifold gaskets.
  5. Install the exhaust manifold and plug wire shields.
  6. If reusing the old fasteners, apply threadlock GM P/N 12345493, (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts.
  7. Install the exhaust manifold bolts. Tighten: Tighten the bolts to 30 N.m (22 lb ft).
  8. Install the spark plugs.
  9. Position the spark plug wire retainer to the engine.
  10. Loosely install the spark plug wire retainer bolt.
  11. Connect the spark plug wires to the spark plugs.
  12. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-277938-S42202594572008012100000) .
  13. Tighten the spark plug wire retainer bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
  14. Align the hinge clip with the lip on the throttle body. In order to install the air cleaner outlet duct, pivot the air cleaner outlet duct downward until the mounting stud is through the hole.
  15. Install the air cleaner adapter nut.
  16. Install the PCV hose.
  17. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor.
  18. Raise the vehicle.
  19. Install the right exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  20. Lower the vehicle.

Exhaust Manifold Replacement - Right Side (4.8L, 5.3L, and 6.0L Engines)

  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the exhaust manifold pipe nuts.
  3. Lower the vehicle.
  4. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-and-60l-introduction-2-of-2) .
  5. Remove the exhaust manifold bolts, manifold, and gasket.
  6. Discard the gasket.
  7. Remove the heat shield bolts (1), and shield (2) from the exhaust manifold (1), if necessary.
  8. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-48l-53l-and-60l-4-of-4__exhaust-manifold-cleaning-and-inspection) .

Note. Refer to FASTENER NOTICE .

  1. Install the heat shield (2), and bolts (1) to the exhaust manifold (1), if necessary. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts.
  3. Install the exhaust manifold, NEW gasket and bolts. Tighten: Tighten the bolts a first pass to 15 N.m (11 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the bolts a final pass to 25 N.m (18 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
  4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.
  5. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-and-60l-introduction-2-of-2) .
  6. Raise the vehicle.
  7. Install the exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  8. Lower the vehicle.
  1. Raise the vehicle enough in order to work through the wheelhouse opening. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  3. Remove the exhaust manifold heat shield bolts.
  4. Remove the exhaust manifold heat shield.
  5. Remove the right exhaust pipe to the exhaust manifold bolts (3, 4, and 5).
  6. Remove the exhaust manifold bolts and nuts in the proper sequence.
  7. Remove the exhaust manifold.
  8. Remove the bolt for the oil level indicator tube bracket in order to remove the exhaust manifold gasket.
  9. Remove and discard the exhaust manifold gasket.
  10. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-66l-4-of-5__exhaust-manifold-cleaning-and-inspection) .
  1. Install the exhaust manifold gasket to the cylinder head.
  2. Install the bolt for the oil level indicator tube bracket. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
  3. Install the exhaust manifold.
  4. Install the exhaust manifold bolts/nuts.
  5. Using the sequence shown, properly tighten the exhaust manifold bolts. Tighten: Tighten the bolt/nuts to 38 N.m (28 lb ft).
  6. Install the exhaust manifold heat shield.
  7. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  8. Install the exhaust pipe gasket. Align the tab on the gasket to face outward.
  9. Install the exhaust pipe bolts (3, 4, and 5). Tighten: Tighten the bolts to 53 N.m (39 lb ft).
  10. Install the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  11. Lower the vehicle.
  1. Remove the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  2. Remove the oil level indicator. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-81l) . IMPORTANT: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug or the wire could be damaged.
  3. Remove the spark plug wires from the spark plugs and ignition coils.
  4. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-and-60l-introduction-2-of-2) .
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  6. Remove the exhaust manifold heat shield bolts and nuts.
  7. Remove the exhaust manifold heat shield.
  8. Lower the vehicle.
  9. Remove the exhaust manifold bolt and nuts.
  10. Remove the exhaust manifold.
  11. Remove and discard the exhaust manifold gasket.
  12. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-81l__exhaust-manifold-cleaning-and-inspection) .
  1. Install the a NEW exhaust manifold gasket.
  2. Install the exhaust manifold. NOTE: Refer to «Fastener Notice»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/oem-general-information/#warnings-and-cautions__fastener-notice) .
  3. Install the exhaust manifold bolt and nuts. Tighten: Tighten the bolt to 35 N.m (26 lb ft). Tighten the nuts to 16 N.m (12 lb ft).
  4. Raise and suitably support the vehicle with safety stands.
  5. Install the exhaust manifold heat shield.
  6. Install the exhaust manifold heat shield bolts and nuts. Tighten: Tighten the bolts/nuts to 25 N.m (18 lb ft).
  7. Lower the vehicle.
  8. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/testing-diagnostics/#engine-controls-and-fuel-48l-53l-and-60l-introduction-2-of-2) .
  9. Install the spark plug wires to the spark plugs and ignition coils.
  10. Install the oil level indicator. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-81l) .
  11. Install the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Loosen the catalytic converter coupling nuts (1).
  3. Loosen the exhaust pipe clamp.
  4. Slide the exhaust pipe clamp up onto the exhaust pipe.
  5. Slide the catalytic converter hanger out from the insulator.
  6. Gently pry up the catalytic converter coupling clip (1) (on the muffler end) in order to disengage the locator button (3) from the coupling clip.
  7. Remove the catalytic converter.
  8. If equipped with an automatic transmission, remove the transmission fluid fill tube to bellhousing nuts.
  9. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.
  10. Lower the vehicle.
  11. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).
  12. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
  13. Remove the turbocharger upper heat shield bolts.
  14. Remove the turbocharger upper heat shield.
  15. Remove the exhaust outlet heat shield bolts.
  16. Remove the exhaust outlet heat shield.
  17. Remove the exhaust outlet to right exhaust pipe bracket bolt.
  18. Loosen the exhaust outlet pipe clamp.
  19. Remove the exhaust outlet pipe.
  1. Install the exhaust outlet pipe.
  2. Tighten the exhaust outlet pipe clamp. Tighten: Tighten the clamp to 15 N.m (11 lb ft).
  3. Install the exhaust outlet to right exhaust pipe bracket bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
  4. Install the exhaust outlet heat shield.
  5. Install the exhaust outlet heat shield bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  6. Install the turbocharger upper heat shield.
  7. Install the turbocharger upper heat shield bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  8. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/mechanical/#engine-mechanical-66l-2-of-5) .
  9. Remove the hood hinge bolts (1) from the service position (2) and position the hood in the normal position. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  10. Raise the vehicle.
  11. If equipped with an automatic transmission, position the transmission fluid fill tube to the studs.
  12. Install the transmission fluid fill tube to bellhousing nuts. Tighten: Tighten the nuts to 18 N.m (13 lb ft).
  13. Position the catalytic converter.
  14. Align the catalytic converter coupling groove (2) to the muffler locator button (3).
  15. Install the catalytic converter until the muffler locator button is fully engaged by the coupling clip (1).
  16. Slide the catalytic converter hanger into the insulator.
  17. Slide the exhaust pipe clamp down.
  18. Tighten the exhaust pipe clamp. Tighten: Tighten the clamp to 15 N.m (11 lb ft).
  19. Tighten both catalytic converter coupling nuts (1) until snug.
  20. Once snug, tighten the catalytic converter coupling nuts to specifications. Tighten: Tighten the nuts to 45 N.m (33 lb ft).
  21. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Support the transmission with a suitable transmission jack.
  3. Remove the transmission mount to transmission support nuts.
  4. Raise the transmission off of the transmission support.
  5. Remove the transmission support crossmember bolts.
  6. Remove the transmission support crossmember.
  7. Depending on which side is being replaced, perform one of the following steps: Remove the exhaust muffler nuts. or Loosen the exhaust pipe clamp.
  8. Remove the necessary exhaust system hangers so that the pipes can be separated.
  9. Use a jack stand to support the exhaust.
  10. Remove the clip around the engine harness and the oxygen sensor pigtail.
  11. Disconnect the connector position assurance (CPA) retainer.
  12. Disconnect the oxygen sensor electrical connector.
  13. Remove the oxygen sensor.
  14. Remove the exhaust manifold pipe nuts.
  15. Using the transmission jack, lower the transmission slightly.
  16. Remove the exhaust manifold pipe.
  17. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket.
  18. Discard the exhaust manifold pipe seal.
  19. If equipped with a 6.0L engine, with regular production option (RPO) Y91, remove the exhaust manifold pipe.
  20. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket.
  21. Discard the exhaust manifold pipe seal.
  1. If equipped with a 6.0L engine, with RPO Y91, install a new exhaust manifold pipe seal to the exhaust manifold pipe.
  2. Install the exhaust manifold pipe.
  3. Apply lubricant to the exhaust pipe hanger bracket, in order to aid in installation.
  4. Slide the exhaust manifold pipe hanger into the exhaust pipe hanger bracket.
  5. Install a new exhaust manifold pipe seal to the exhaust manifold pipe.
  6. Install the exhaust manifold pipe.
  7. Apply lubricant to the exhaust pipe hanger bracket, in order to aid in installation.
  8. Slide the exhaust manifold pipe hanger into the exhaust pipe hanger bracket.
  9. Install the exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (39 lb ft).
  10. Using the transmission jack, raise the transmission.
  11. If the exhaust manifold pipe was replaced perform the following: Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensor. Install the old oxygen sensor. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  12. If the exhaust manifold pipe was not replaced perform the following: Connect the oxygen sensor electrical connector. Connect the CPA retainer. Install the clip around the engine harness and the oxygen sensor pigtail.
  13. Install the exhaust pipe/catalytic converter to the vehicle.
  14. Install the exhaust system hangers.
  15. Depending on which side is being replaced, perform one of the following steps: Install the exhaust muffler nuts. Tighten: Tighten the nuts to 40 N.m (30 lb ft). or Install a NEW exhaust pipe clamp. Tighten: Tighten the clamp to 44 N.m (33 lb ft).
  16. Install the transmission support crossmember.
  17. Install the transmission support crossmember bolts. Tighten: Tighten the bolts to 95 N.m (70 lb ft).
  18. Lower the transmission onto the transmission support.
  19. Install the transmission mount to transmission support nuts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  20. Remove the support from the transmission.
  21. Lower the vehicle.
  1. Remove the right wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  2. Remove the exhaust heat shield nuts (2) and heat shield (3) from the dash panel.
  3. Remove the left exhaust pipe heat shield bolts.
  4. Remove the heat shield.
  5. Remove the exhaust pipe bolts in the proper sequence.
  6. Remove the exhaust pipe and gaskets.
  7. Discard the gaskets.
  1. Position the exhaust pipe with a NEW gasket to the turbocharger. Align the tab on the gasket at the turbocharger to face inward.
  2. Loosely install the bolts.
  3. Position the exhaust pipe with a NEW gasket to the exhaust manifold. Align the tab on the gasket to face outward.
  4. Loosely install the bolts.
  5. Tighten the exhaust pipe bolts in the sequence shown. Tighten: Tighten the bolts to 53 N.m (39 lb ft).
  6. Install the exhaust pipe heat shield bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  7. Install the left side exhaust heat shield (3) at the dash panel.
  8. Install the heat shield nuts (2). Tighten: Tighten the nuts to 9 N.m (80 lb in).
  9. Install the right wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  1. Remove the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  2. Remove the exhaust pipe bolts in the proper sequence.
  3. Remove the exhaust pipe, bracket and gaskets.
  4. Discard the gaskets.
  1. Position the exhaust pipe with a NEW gasket to the turbocharger. Align the tab on the gasket at the turbocharger to face inward.
  2. Loosely install the bolts.
  3. Position the exhaust pipe with a NEW gasket to the exhaust manifold. Align the tab on the gasket to face outward.
  4. Loosely install the bolts.
  5. Tighten the exhaust pipe bolts in the proper sequence. Tighten: Tighten the bolts to 53 N.m (39 lb ft).
  6. Remove the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: Remove the clip from around the engine harness and the oxygen sensor pigtail. Disconnect the connector position assurance (CPA) retainer. Disconnect the forward oxygen sensor electrical connector.
  3. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: Unclip the oxygen sensor electrical connector from the hose clip. Disconnect the CPA retainer. Disconnect the oxygen sensor electrical connector (1).
  4. If equipped with a 6.0L or 8.1L engine, perform the following: Disconnect the CPA retainer. Disconnect the oxygen sensor electrical connector (1).
  5. Support the catalytic converter or exhaust manifold pipe with adjustable jackstands.
  6. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the left exhaust manifold pipe nuts.
  7. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the right exhaust manifold pipe nuts.
  8. If equipped with a 6.0L or 8.1L engine, remove the right exhaust manifold pipe nuts.
  9. If equipped with a 6.0L or 8.1L engine, perform the following: Remove the left exhaust manifold pipe nuts. Remove the exhaust hanger mounting bracket bolts.
  10. Lower the catalytic converter or exhaust manifold pipe using the adjustable jackstands.
  11. Remove the exhaust manifold pipe seal(s).
  1. Install the exhaust manifold pipe seal(s).
  2. Raise the catalytic converter or exhaust manifold pipe using the adjustable jackstands.
  3. If equipped with a 6.0L or 8.1L engine, perform the following: Install the exhaust hanger mounting bracket bolts. Install the left exhaust manifold pipe nuts. Tighten: Tighten the bolts to 12 N.m (106 lb in). Tighten the nuts to 50 N.m (39 lb ft).
  4. If equipped with a 6.0L or 8.1L engine, install the right exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (39 lb ft).
  5. If equipped with a 4.3L, 4.8L, or 5.3L engine, install the right exhaust manifold pipe nuts.
  6. If equipped with a 4.3L, 4.8L, or 5.3L engine, install the left exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (39 lb ft).
  7. If equipped with a 6.0L or 8.1L engine, perform the following: Connect the oxygen sensor electrical connector (1). Connect the CPA retainer.
  8. Remove the adjustable jackstands from catalytic converter or exhaust manifold pipe.
  9. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: Connect the oxygen sensor electrical connector (1). Connect the CPA retainer. Clip the oxygen sensor electrical connector to the hose clip.
  10. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: Connect the forward oxygen sensor electrical connector. Connect the CPA retainer. Install the clip around the engine harness and the oxygen sensor pigtail.
  11. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. If equipped, unclip the oxygen sensor connection from the floor reinforcement.
  3. Disconnect the oxygen sensor electrical connector.
  4. Remove the oxygen sensor clips from the frame.
  5. Disconnect the connector position assurance (CPA) retainers.
  6. Disconnect the oxygen sensor electrical connectors.
  7. Unclip the oxygen sensors electrical connectors from the following: Hose clip Transmission crossmember
  8. Disconnect the CPA retainers.
  9. Disconnect the oxygen sensor electrical connectors (1, 2).
  10. Remove the left exhaust manifold pipe nuts.
  11. Remove the right exhaust manifold pipe nuts.
  12. Remove the exhaust muffler nuts.
  13. Remove the catalytic converter.
  14. If necessary, remove the oxygen sensors.

Note. Refer to FASTENER NOTICE .

  1. If necessary, install the oxygen sensors. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. Install the oxygen sensors. Tighten: Tighten the sensors to 42 N.m (31 lb ft).
  2. Install the catalytic convertor.
  3. Install NEW exhaust manifold pipe seals to the exhaust manifolds.
  4. Install the right exhaust manifold pipe nuts until snug.
  5. Install the left exhaust manifold pipe nuts until snug.
  6. Tighten the exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (39 lb ft).
  7. Install the exhaust muffler nuts. Tighten: Tighten the nuts to 40 N.m (30 lb ft).
  8. Connect the oxygen sensor electrical connectors (1, 2).
  9. Connect the CPA retainers.
  10. Clip the oxygen sensors electrical connectors to the following: Hose clip Transmission crossmember
  11. Connect the oxygen sensor electrical connectors.
  12. Connect the CPA retainers.
  13. Install the clip around the engine harness and the oxygen sensor pigtail.
  14. Connect the oxygen sensor electrical connector.
  15. If equipped, clip the oxygen sensor connection to the floor reinforcement.
  16. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Support the transmission with a suitable transmission jack.
  3. Remove the transmission mount to transmission support nuts.
  4. Raise the transmission off of the transmission support.
  5. Remove the transmission support crossmember bolts.
  6. Remove the transmission support crossmember.
  7. Depending on which side is being replaced, perform one of the following steps: Remove the exhaust muffler nuts. or Loosen the exhaust pipe clamp.
  8. Remove the necessary exhaust system hangers so that the pipes can be separated.
  9. Use a jack stand to support the exhaust.
  10. Disconnect the connector position assurance (CPA) retainers.
  11. Disconnect the oxygen sensor electrical connectors (1, 2).
  12. Loosen the right exhaust manifold pipe nuts.
  13. Remove the left exhaust manifold pipe nuts.
  14. Using the transmission jack, lower the transmission slightly.
  15. Remove the catalytic converter.
  16. Slide the catalytic converter hanger out of the exhaust pipe hanger bracket.
  17. If equipped with a 6.0L engine, with regular production option (RPO) Y91, remove the catalytic converter.
  18. Slide the catalytic converter hanger out of the exhaust pipe hanger bracket.
  19. Remove the oxygen sensors if the catalytic converter is to be replaced.

Note. Refer to Fastener Notice .

  1. If the catalytic converter was replaced, perform the following: Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. Install the oxygen sensors. Tighten: Tighten the sensors to 42 N.m (31 lb ft).
  2. If equipped with a 6.0L engine, with RPO Y91, install a NEW exhaust seal to the exhaust manifold.
  3. Install the catalytic converter. Slide the catalytic converter hanger into the exhaust pipe hanger bracket.
  4. Install a NEW exhaust seal to the exhaust manifold.
  5. Install the catalytic converter. Slide the catalytic converter hanger into the exhaust pipe hanger bracket.
  6. Install the left exhaust manifold pipe nuts.
  7. Tighten the right exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (39 lb ft).
  8. Using the transmission jack, raise the transmission slightly.
  9. Connect the oxygen sensor electrical connectors (1, 2).
  10. Connect the CPA retainers.
  11. Install the exhaust pipe/catalytic converter to the vehicle.
  12. Install the exhaust system hangers.
  13. Depending on which side is being replaced, perform one of the following steps: Install the exhaust muffler nuts. Tighten: Tighten the nuts to 40 N.m (30 lb ft). or Install a NEW exhaust pipe clamp. Tighten: Tighten the clamp to 44 N.m (33 lb ft).
  14. Install the transmission support crossmember.
  15. Install the transmission support crossmember bolts. Tighten: Tighten the bolts to 95 N.m (70 lb ft).
  16. Lower the transmission onto the transmission support.
  17. Install the transmission mount to transmission support nuts. Tighten: Tighten the nuts to 40 N.m (30 lb ft).
  18. Remove the support from the transmission.
  19. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Support the transmission with a suitable transmission jack.
  3. Remove the transmission mount to transmission support nuts.
  4. Raise the transmission off of the transmission support.
  5. Remove the transmission support crossmember bolts.
  6. Remove the transmission support crossmember.
  7. Loosen the catalytic converter coupling nuts (1).
  8. Loosen the exhaust pipe clamp.
  9. Slide the exhaust pipe clamp up onto the exhaust pipe.
  10. Slide the catalytic converter hanger out of the insulator.
  11. Gently pry up the catalytic converter coupling clip (1) (on the muffler end) in order to disengage the locator button (3) from the coupling clip.
  12. Remove the catalytic converter.
  13. Gently pry up the catalytic converter coupling clip (1) (on the catalytic converter end).
  14. Slide the catalytic converter coupling off the catalytic converter.
  1. Align the catalytic converter coupling groove to the catalytic converter locator button.
  2. Install the catalytic converter coupling until the catalytic converter locator button is fully engaged by the coupling clip.
  3. Position the catalytic converter.
  4. Align the catalytic converter coupling groove (2) to the muffler locator button (3).
  5. Install the catalytic converter until the muffler locator button is fully engaged by the coupling clip (1).
  6. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation.
  7. Slide the catalytic converter hanger into the insulator.
  8. Slide the exhaust pipe clamp down.
  9. Tighten the exhaust pipe clamp. Tighten: Tighten the clamp to 15 N.m (11 lb ft).
  10. Tighten both catalytic converter coupling nuts (1) until snug.
  11. Once snug, tighten the catalytic converter coupling nuts to specifications. Tighten: Tighten the nuts to 45 N.m (33 lb ft).
  12. Install the transmission support crossmember.
  13. Install the transmission support crossmember bolts. Tighten: Tighten the bolts to 95 N.m (70 lb ft).
  14. Lower the transmission onto the transmission support.
  15. Install the transmission mount to transmission support nuts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  16. Remove the support from the transmission.
  17. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the exhaust muffler hanger nuts.
  3. Remove the hanger from the hanger insulator.
  1. Install the hanger into the hanger insulator.
  2. Install the exhaust muffler hanger nuts. Tighten: Tighten the nuts to 50 N.m (39 lb ft).
  3. Lower the vehicle.
  1. Remove the exhaust manifold pipe. Refer to «Exhaust Manifold Pipe Replacement (6.0L, and 8.1L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  2. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.0L and 8.1L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L Engine)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  3. If equipped with a 4L60-E automatic transmission, remove the exhaust pipe hanger bracket bolts.
  4. If equipped with a 6.0L engine and a 4L80-E automatic transmission, remove the exhaust pipe hanger bracket bolts.
  5. If equipped with a 6.0L, or 8.1L engine and a 4L80-E automatic transmission, remove the exhaust pipe hanger bracket bolts.
  6. If equipped with a 6.0L engine and a 5-speed manual transmission, remove the transmission bolts.
  7. If equipped with a 6.0L engine and a 5-speed manual transmission, remove the exhaust pipe hanger bracket bolts.
  8. If equipped with a 6.6L or 8.1L engine and a Allison transmission, remove the exhaust pipe hanger bracket bolts.
  9. If equipped with a 6.6L or 8.1L engine and a 6-speed manual transmission, remove the exhaust pipe hanger bracket bolts.
  10. Remove the exhaust manifold pipe bracket.
  1. Install the exhaust manifold pipe bracket.
  2. If equipped with a 6.6L or 8.1L engine and a 6-speed manual transmission, install the exhaust pipe hanger bracket bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  3. If equipped with a 6.6L or 8.1L engine and a Allison transmission, install the exhaust pipe hanger bracket bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  4. If equipped with a 6.0L engine and a 5-speed manual transmission, install the exhaust pipe hanger bracket bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  5. If equipped with a 6.0L engine and a 5-speed manual transmission, install the transmission bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
  6. If equipped with a 6.0L or 8.1L engine and a 4L80-E automatic transmission, install the exhaust pipe hanger bracket bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  7. If equipped with a 6.0L engine and a 4L80-E automatic transmission, install the exhaust pipe hanger bracket bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  8. If equipped with a 4L60-E automatic transmission, install the exhaust pipe hanger bracket bolts. Tighten: Tighten the bolts to 17 N.m (13 lb ft).
  9. Install the catalytic converter. Refer to «Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.0L and 8.1L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L Engine)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  10. Install the exhaust manifold pipe. Refer to «Exhaust Manifold Pipe Replacement (6.0L, and 8.1L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the exhaust muffler nuts.
  3. Apply lubricant to the exhaust insulators in order to aid in removal.
  4. Remove the muffler brackets from the insulators.
  5. Remove the exhaust muffler.
  1. Apply lubricant to the exhaust insulators in order to aid in installation.
  2. Install the muffler to the insulators.
  3. Install the exhaust muffler nuts. Tighten: Tighten the nuts to 40 N.m (30 lb ft).
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the spare tire, if necessary.
  3. Install adjustable jack stands under the rear axle, if necessary.
  4. If equipped with a 8.6 or 9.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary.
  5. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.
  6. If equipped with a 10.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary.
  7. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.
  8. Remove the rear shock absorbers lower bolts and nuts, if necessary.
  9. Lower the rear axle using the adjustable jack stands, if necessary.
  10. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler nuts.
  11. Loosen the exhaust pipe clamp.
  12. With the aid of an assistant, support the exhaust muffler.
  13. If equipped with a 6.6L engine, loosen the catalytic converter coupling nuts (1).
  14. With the aid of an assistant, support the exhaust muffler.
  15. If equipped with a 6.0L or 8.1L engine, remove the insulators from the frame hangers.
  16. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the catalytic converter.
  17. Remove the insulators from the muffler hangers.
  18. Remove the exhaust manifold pipe gasket, if necessary.
  19. If equipped with a 6.6L engine, gently pry up the catalytic converter coupling clip (1) (on the muffler end) in order to disengage the locator button (3) from the coupling clip.
  20. With the aid of an assistant, slide the muffler rearward until the locator button is fully disengaged.
  21. If equipped with a 6.6L engine, remove the insulators from the frame hangers with the aid of an assistant.
  22. Remove the exhaust muffler gasket, if necessary.
  23. Remove the insulators from the muffler hangers.
  24. If equipped with a 6.0L or 8.1L engine, remove the oxygen sensor if the muffler is being replaced.
  25. If the muffler is NOT being replaced as an assembly, the band clamp MUST be replaced. Perform the following: Mark the position of the band clamp on the intermediate exhaust pipe. Remove the band clamp from the exhaust pipe by grinding the weld. Install a NEW band clamp onto the exhaust pipe.
  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.
  3. Install the oxygen sensor. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  4. If equipped with a 6.6L engine, using the aid of an assistant, align the muffler locator button (3) to the catalytic converter coupling groove (2).
  5. Install the muffler until the locator button is fully engaged by the coupling clip (1).
  6. If equipped with a 6.6L engine, install the insulators to the muffler hangers.
  7. Install a new exhaust muffler gasket.
  8. Install the insulators to the frame hangers.
  9. If equipped with a 6.0L or 8.1L engine, install the insulators to the muffler hangers.
  10. Install a new exhaust manifold pipe gasket.
  11. With the aid of an assistant, slide the muffler forward in order to install the muffler to the catalytic converter.
  12. Install the insulators to the frame hangers.
  13. If equipped with a 6.6L engine, tighten the catalytic converter coupling nuts until snug.
  14. Once snug, tighten the catalytic converter coupling nuts (1) to specifications. Tighten: Tighten the nuts to 45 N.m (33 lb ft).
  15. 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.
  16. Install the exhaust muffler nuts.
  17. 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).
  18. Raise the rear axle using the adjustable jack stands, if necessary.
  19. Install the rear shock absorbers lower bolts and nuts, if necessary. Tighten: Tighten the bolts to 95 N.m (70 lb ft).
  20. If equipped with a 10.5 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. If equipped with a 8.6 or 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  23. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  24. Remove the adjustable jack stands from under the rear axle, if necessary.
  25. Install the spare tire, if necessary.
  26. Lower the vehicle.
  1. Remove the exhaust manifold pipe, if necessary. Refer to «Exhaust Manifold Pipe Replacement (6.0L, and 8.1L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  2. Remove the catalytic converter, if necessary. Refer to «Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.0L and 8.1L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L Engine)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  3. Remove the exhaust front heat shield nuts.
  4. Remove the exhaust front heat shield from the studs.
  5. If vehicle is a regular cab pick-up truck, remove the exhaust heat shield nuts.
  6. Remove the exhaust front heat shield (1) and/or the exhaust heat shield (2) from the studs.
  7. If vehicle is a extended cab pick-up truck, remove the exhaust heat shield nuts.
  8. Remove the exhaust heat shield (1, 2) from the studs.
  9. If vehicle is a crew cab pick-up truck, remove the exhaust heat shield nuts.
  10. Remove the exhaust heat shields from the studs.
  1. If vehicle is a crew cab pick-up truck, install the exhaust heat shields to the studs.
  2. Install the exhaust heat shield nuts. Tighten: Tighten the exhaust heat shield nuts to 9 N.m (80 lb in).
  3. If vehicle is a extended cab pick-up truck, install the exhaust heat shield (1, 2) to the studs.
  4. Install the exhaust heat shield nuts. Tighten: Tighten the exhaust heat shield nuts to 9 N.m (80 lb in).
  5. If vehicle is a regular cab pick-up truck, install the exhaust front heat shield (1) and/or the exhaust heat shield (2) to the studs.
  6. Install the exhaust heat shield nuts. Tighten: Tighten the exhaust heat shield nuts to 9 N.m (80 lb in).
  7. Install the exhaust front heat shield to the studs.
  8. Install the exhaust front heat shield nuts. Tighten: Tighten the exhaust heat shield nuts to 9 N.m (80 lb in).
  9. Install the catalytic converter, if necessary. Refer to «Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.0L and 8.1L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L Engine)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  10. Install the exhaust manifold pipe, if necessary. Refer to «Exhaust Manifold Pipe Replacement (6.0L, and 8.1L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  1. Remove the exhaust muffler. Refer to «Muffler Replacement (4.3L, 4.8L, and 5.3L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Muffler Replacement (6.0L, 6.6L, and 8.1L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  2. Remove the spare tire hoist. Refer to «Spare Wheel Hoist and Shaft Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/wheel-tire-system/#tires-and-wheels) .
  3. If equipped with a 6 1/2 ft box, remove the exhaust heat shield bolts.
  4. Remove the exhaust heat shield.
  5. If equipped with a 8 ft box, remove the exhaust heat shield bolts.
  6. Remove the exhaust heat shield.
  1. If equipped with a 8 ft box, install the exhaust heat shield.
  2. Install the exhaust heat shield bolts. Tighten: Tighten the exhaust heat shield bolts to 9 N.m (80 lb in).
  3. If equipped with a 6 1/2 ft box, install the exhaust heat shield.
  4. Install the exhaust heat shield bolts. Tighten: Tighten the exhaust heat shield bolts to 9 N.m (80 lb in).
  5. Install the spare tire hoist. Refer to «Spare Wheel Hoist and Shaft Replacement»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/wheel-tire-system/#tires-and-wheels) .
  6. Install the exhaust muffler. Refer to «Muffler Replacement (4.3L, 4.8L, and 5.3L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Muffler Replacement (6.0L, 6.6L, and 8.1L Engines)»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the exhaust heat shield nuts.
  3. Remove the exhaust heat shield (1, 3) from the dash panel studs.
  4. If removing the heat shield (3), remove the shield out thru the passenger side wheelwell.
  1. If installing the heat shield (3), install the shield thru the passenger side wheelwell.
  2. Install the exhaust heat shield (1, 3) to the dash panel studs. NOTE: Refer to «FASTENER NOTICE»(/chevrolet/cab-chassis-silverado-3500/2003-2012/remont/oem-general-information/#warnings-and-cautions__fastener-notice) .
  3. Install the exhaust heat shield nuts. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  4. Lower the vehicle.

Exhaust System Description

IMPORTANTUse of non-OEM parts may cause driveability concerns.

The exhaust system carries exhaust gases, treated by the catalytic converter, through a resonator, if applicable and into the exhaust muffler where exhaust noise is lessened.

In order to secure the exhaust pipe to the exhaust manifold, a flange and seal-joint coupling is utilized. The exhaust system may utilize a slip-joint coupling design with a clamp and a U-bolt or a flange connection with a gasket.

Exhaust hangers and rubber insulators help to support the weight of the exhaust pipe along with insulating any exhaust system vibration, rattle, or noise.

Exhaust hangers also space the exhaust system away from the underbody of the vehicle and allows the exhaust system to expand as the exhaust system warms up.

Exhaust heat shields are used to protect the body and other components from damage due to the heat from the exhaust system.

The exhaust system may be comprised of the following components

  1. Exhaust manifold
  2. Exhaust pipes
  3. Catalytic converters
  4. Exhaust muffler
  5. Exhaust resonator, if equipped
  6. Exhaust tail pipe, if equipped
  7. Exhaust hangers
  8. Exhaust heat shields

Resonator

Some exhaust systems are equipped with a resonator. The resonator, located either before or after the muffler, allows the use of mufflers with less back pressure. Resonators are used when vehicle characteristics require specific exhaust tuning.

Catalytic Converter

The catalytic converter is an emission control device added to the engine exhaust system in order to reduce hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) pollutants from the exhaust gas.

The catalytic converter is comprised of a ceramic monolith substrate, supported in insulation and housed within a sheet metal shell. The substrate may be washcoated with 3 noble metals

  1. Platium (Pt)
  2. Palladium (Pd)
  3. Rhodium (Rh)

The catalyst in the converter is not serviceable.

Muffler

The exhaust muffler reduces the noise levels of the engine exhaust by the use of tuning tubes. The tuning tubes create channels inside the exhaust muffler that lower the sound levels created by the combustion of the engine.

Special Tools

Special Tools Illustration Tool Number/Description J Exhaust Back Pressure Gage

Scheme 1

Scheme 1: Special Tools
Scheme 1: Special Tools