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Engine Exhaust System Chevrolet Chevy Express H1500

Exhaust 3 illustrations ~6206 words

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
Catalytic Converter Nut (6.6L)40 N.m30 lb ft
Catalytic Converter to Exhaust Pipe Nut (6.0L)48 N.m35 lb ft
Catalytic Converter to Manifold Nut (4.3L/4.8L/5.3L)65 N.m48 lb ft
Catalytic Converter to Muffler Nut (4.3L/4.8L/5.3L/6.0L)48 N.m35 lb ft
Catalytic Converter to Particulate Filter Nut (6.6L)40 N.m30 lb ft
Exhaust Gas Recirculation (EGR) Cooler Pipe Bolt (6.6L)9 N.m80 lb in
Exhaust Gas Recirculation (EGR) Valve Adapter Pipe Bracket Bolt (6.6L)9 N.m80 lb in
Exhaust Hanger Bolt17 N.m13 lb ft
Exhaust Manifold Bolt (4.3L)
First Pass15 N.m11 lb ft
Final Pass30 N.m22 lb ft
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)38 N.m28 lb ft
Exhaust Particulate Filter to Tailpipe Nut (6.6L)40 N.m30 lb ft
Exhaust Pipe Bolt (6.6L)53 N.m39 lb ft
Exhaust Pipe Clamp (6.0L)54 N.m40 lb ft
Exhaust Pipe Clamp (6.6L)40 N.m30 lb ft
Exhaust Pipe Heat Shield Bolt (6.6L)8 N.m71 lb in
Heat Shield Bolt12 N.m106 lb in
Heated Oxygen Sensor42 N.m31 lb ft
Rear Shock Absorber Lower Bolt95 N.m70 lb ft
Spark Plug Wire Support Bolt (4.3L)12 N.m106 lb in
Transmission Fluid Fill Tube Nut (6.6L)18 N.m13 lb ft
Transmission Mount to Support Nut40 N.m30 lb ft
Turbocharger Exhaust Heat Shield Bolt (6.6L)8 N.m71 lb in
Turbocharger Exhaust Pipe Clamp (6.6L)15 N.m11 lb ft
Turbocharger Exhaust Pipe to Catalytic Converter Pipe Clamp (6.6L)40 N.m30 lb ft
Turbocharger Exhaust Pipe to Right Exhaust Pipe Bracket Bolt (6.6L)34 N.m25 lb ft
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/chevy-express-h1500/2003-2012/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/chevy-express-h1500/2003-2012/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/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  2. Poor acceleration Refer to «Restricted Exhaust»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  3. Poor fuel economy Refer to «Restricted Exhaust»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  4. Excessive smoke (diesel) Refer to «Restricted Exhaust»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  5. Exhaust hissing noise Refer to «Exhaust Leakage»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system__exhaust-leakage) .
  6. Exhaust popping noise Refer to «Exhaust Leakage»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system__exhaust-leakage) .
  7. Exhaust rattle noise Refer to «Exhaust Noise»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system__exhaust-noise) .
  8. Loud exhaust noise Refer to «Exhaust Noise»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system__exhaust-noise) .
  9. Exhaust buzz, groan, hum noise Refer to «Exhaust Noise»(/chevrolet/chevy-express-h1500/2003-2012/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 Exhaust Back Pressure Gage. 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.
  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 6.6 L diesel engine?Go to Diagnostic AidsGo to Step 4
4Remove the AIR check valve or the HO2S that is in front of and closest to the catalytic converter. Refer to the following: Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 for the 4.3L engine Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 for the 4.3L engine Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 for the 4.8L, 5.3L and 6.0L engines Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 for the 4.8L, 5.3L, and 6.0L engines Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 for the 6.6L engine Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 for the 6.6L engine Install the J 35314-A Exhaust Back Pressure Gage in place of the AIR check valve or HO2S sensor. Start the engine. Increase and monitor the engine speed at 2000 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 . Re-install the AIR check valve/HO2S sensor. Refer to the following: Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 for the 4.3L engine Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 for the 4.3L engine Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 for the 4.8L, 5.3L, and 6.0L engines Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 for the 4.8L, 5.3L, and 6.0L engines Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 for the 6.6L engine Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 for the 6.6L engine Remove the post-catalyst HO2S sensor. Refer to the following: Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 for the 4.3L engine Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for the 4.3L engine Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 for the 4.8L, 5.3L, and 6.0L engines Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for the 4.8L, 5.3L, and 6.0L engines Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 for the 6.6L engine Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for the 6.6L engine Install the J 35314-A in place of the post HO2S sensor. Start the engine. Increase and monitor the engine speed at 2000 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 (Dual Exhaust - Left) or Catalytic Converter Replacement (Dual Exhaust - Right) or Catalytic Converter Replacement (Single Exhaust - 4.3L, 4.8L and 5.3L) or Catalytic Converter Replacement (6.6L (LBZ/LLY)) or Catalytic Converter Replacement (6.6L (LMM)) . Did you find and correct the condition?Go to Step 8
8Remove the J 35314-A . Reinstall the AIR check valve or the HO2S sensor. Refer to the following: Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 for the 4.3L engine Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for the 4.3L engine Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 for the 4.8L, 5.3L, and 6.0L engines Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for the 4.8L, 5.3L, and 6.0L engines Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 for the 6.6L engine Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for the 6.6L 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 componentsAlign and tighten the components to the specifications. Refer to Fastener Tightening Specifications . Ensure the exhaust hangers are in the proper locations and not loose.
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 connectionsRepair as required or replace the affected component. Refer to the affected components procedure for service.
Exhaust manifold cracked or brokenReplace the exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side (4.8L, 5.3L, 6.0L) or Exhaust Manifold Replacement - Left Side (6.6L) or Exhaust Manifold Replacement - Left Side (4.3L) or Exhaust Manifold Replacement - Right Side (4.3L) or Exhaust Manifold Replacement - Right Side (4.8L, 5.3L, 6.0L) or Exhaust Manifold Replacement - Right Side (6.6L) .
Exhaust system component connection welds leakingReplace the leaking component. Refer to the affected component's procedure for service.
Muffler or resonator (if equipped) damaged or leaking at the seamsReplace the affected muffler or resonator. Refer to one of the following procedures: Muffler Replacement (4.3L, 4.8L, 5.3L, and 6.0L) or Muffler Replacement (6.6L (LBZ/LLY)) 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, 5.3L, and 6.0L) or Muffler Replacement (6.6L (LBZ/LLY)) .
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 (Dual Exhaust - Left) Catalytic Converter Replacement (Dual Exhaust - Right) Catalytic Converter Replacement (Single Exhaust - 4.3L, 4.8L and 5.3L) Catalytic Converter Replacement (6.6L (LBZ/LLY)) Catalytic Converter Replacement (6.6L (LMM)) Muffler Replacement (4.3L, 4.8L, 5.3L, and 6.0L) Muffler Replacement (6.6L (LBZ/LLY))
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 the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the catalytic converter from the exhaust manifold. Refer to «Catalytic Converter Replacement (Dual Exhaust - Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (Dual Exhaust - Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (Single Exhaust - 4.3L, 4.8L and 5.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  3. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  4. Disconnect the EGR valve pipe from the exhaust manifold if equipped.
  5. Remove the spark plug wires.
  6. Remove the exhaust manifold.
  7. Clean all sealing surfaces.

Installation Procedure

  1. Install the exhaust manifold. Tighten: Tighten the exhaust manifold bolts - First Pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts - Second Pass to 25 N.m (18 lb ft).
  2. Connect the EGR valve pipe to the manifold.
  3. Install the spark plug wires.
  4. Install the exhaust pipe to the exhaust manifold.
  5. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .

Scheme 1

Scheme 1: Exhaust Manifold Replacement - Left Side (6.6L)
Scheme 1: Exhaust Manifold Replacement - Left Side (6.6L)
CalloutComponent Name
Preliminary Procedures Remove the engine cover. Refer to Engine Cover Replacement . Remove the left exhaust pipe. Refer to Exhaust Pipe Replacement - Left Side (6.6L (LBZ/LLY)) or Exhaust Pipe Replacement - Left Side (6.6L (LMM)) . Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Exhaust Manifold Nut (Qty: 2) NOTE: Refer to Fastener Notice . Tip: Torque the bolts/nuts to the sequence shown. Tighten: 38 N.m (28 lb ft)
2Exhaust Manifold Bolt (Qty: 6) Tip: Torque the bolts/nuts to the sequence shown. Tighten: 38 N.m (28 lb ft)
3Left Exhaust Manifold
4Exhaust Manifold Gasket
NOTE
Refer to Fastener Notice .

Exhaust Manifold Replacement - Left Side (6.6L)

  1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  2. Disconnect the engine coolant temperature (ECT) gage sensor electrical connector.
  3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  4. Remove the left front tire. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-h1500/2003-2012/remont/wheel-tire-system/#tires-and-wheels) .
  5. Remove the left fender wheelhouse extension (1).
  6. Remove the catalytic converter assembly. Refer to «Catalytic Converter Replacement (Dual Exhaust - Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (Dual Exhaust - Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (Single Exhaust - 4.3L, 4.8L and 5.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  7. Remove the exhaust gas recirculation (EGR) valve inlet pipe from the exhaust manifold.
  8. Remove the spark plug wires from the spark plugs.
  9. Remove the spark plug wire support bolts.
  10. Remove the spark plug wire support with the spark plug wires.
  11. Remove the spark plugs.
  12. Remove the exhaust manifold bolts and studs.
  13. Remove the spark plug wire shields, if applicable.
  14. Remove the exhaust manifold.
  15. Remove and discard the exhaust manifold gaskets.
  1. Sub-assemble the NEW gaskets, the spark plug wire shields, and the bolts to the exhaust manifold.
  2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
  3. Install the exhaust manifold. Tighten: Tighten the exhaust manifold bolts - First Pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts - Second Pass to 30 N.m (22 lb ft).
  4. Install the spark plugs.
  5. Install the spark plug wires to the spark plugs.
  6. Install the spark plug wire support and bolts. Tighten: Tighten the spark plug wire support bolts to 12 N.m (106 lb in).
  7. Install the EGR valve inlet pipe to the exhaust manifold. Tighten: Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N.m (22 lb ft).
  8. Install the catalytic converter assembly. Refer to «Catalytic Converter Replacement (Dual Exhaust - Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (Dual Exhaust - Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (Single Exhaust - 4.3L, 4.8L and 5.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  9. Install the fender wheelhouse extension (1).
  10. Install the left front tire.
  11. Lower the vehicle.
  12. Connect the ECT gage sensor electrical connector.
  13. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the right front tire.
  3. Remove the right fender wheelhouse extension (1).
  4. Disconnect the spark plug wires from the spark plugs.
  5. Remove the bolts and the spark plug wire support.
  6. Remove the starter. Refer to «Starter Motor Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Starter Motor Replacement (4.8L, 5.3L, and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Starter Motor Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  7. Remove the catalytic converter assembly. Refer to «Catalytic Converter Replacement (Dual Exhaust - Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (Dual Exhaust - Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (Single Exhaust - 4.3L, 4.8L and 5.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  8. Remove the exhaust manifold bolts through the wheelhouse.
  9. Remove the exhaust manifold with the exhaust manifold gaskets and the spark plug wire shields from the engine.
  10. Clean all gasket surfaces.
  1. Sub-assemble the NEW gaskets, the spark plug wire shields, and the bolts to the exhaust manifold.
  2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
  3. Install the exhaust manifold. Tighten: Tighten the exhaust manifold bolts - First Pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts - Second Pass to 30 N.m (22 lb ft).
  4. Install the catalytic converter assembly. Refer to «Catalytic Converter Replacement (Dual Exhaust - Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (Dual Exhaust - Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (Single Exhaust - 4.3L, 4.8L and 5.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  5. Install the starter. Refer to «Starter Motor Replacement (4.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Starter Motor Replacement (4.8L, 5.3L, and 6.0L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Starter Motor Replacement (6.6L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  6. Install the spark plug wire support and bolts. Tighten: Tighten the spark plug wire support bolts to 12 N.m (106 lb in).
  7. Install the spark plug wires. Refer to «Spark Plug Wire Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-43l-introduction-2-of-2) .
  8. Install the fender wheelhouse extension (1).
  9. Install the front tire. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-h1500/2003-2012/remont/wheel-tire-system/#tires-and-wheels) .
  10. Lower the vehicle.
  1. Remove the catalytic converter from the exhaust manifold. Refer to «Catalytic Converter Replacement (Dual Exhaust - Left)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (Dual Exhaust - Right)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (Single Exhaust - 4.3L, 4.8L and 5.3L)»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  2. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  3. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Removal»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-48l-53l-and-60l-2-of-4__oil-level-indicator-and-tube-removal) .
  4. Remove the exhaust manifold, bolts and exhaust manifold.
  5. Clean all sealing surfaces.
  1. Install the exhaust manifold and bolts. Tighten: Tighten the exhaust manifold bolts - First Pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts - Second Pass to 25 N.m (18 lb ft).
  2. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Removal»(/chevrolet/chevy-express-h1500/2003-2012/remont/mechanical/#engine-mechanical-48l-53l-and-60l-2-of-4__oil-level-indicator-and-tube-removal) .
  3. Install the catalytic converter to the exhaust manifold.
  4. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .

Scheme 2

Scheme 2: Exhaust Manifold Replacement - Right Side (6.6L)
Scheme 2: Exhaust Manifold Replacement - Right Side (6.6L)
CalloutComponent Name
Preliminary Procedures Remove the engine cover. Refer to Engine Cover Replacement . Remove the turbocharger exhaust pipe. Refer to Turbocharger Exhaust Pipe Replacement (6.6L (LBZ/LLY)) or Turbocharger Exhaust Pipe Replacement (6.6L (LMM)) . Remove the right exhaust pipe. Refer to Exhaust Pipe Replacement - Right Side (6.6L (LBZ/LLY)) or Exhaust Pipe Replacement - Right Side (6.6L (LMM)) . Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front tire and wheel. Refer to Tire and Wheel Removal and Installation .
1Exhaust Manifold Nut (Qty: 2) NOTE: Refer to Fastener Notice . Tip: Torque the bolts/nuts to the sequence shown. Tighten: 38 N.m (28 lb ft)
2Exhaust Manifold Bolt (Qty: 6) Tip: Torque the bolts/nuts to the sequence shown. Tighten: 38 N.m (28 lb ft)
3Right Exhaust Manifold
4Exhaust Manifold Gasket
NOTE
Refer to Fastener Notice .

Exhaust Manifold Replacement - Right Side (6.6L)

  1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  2. Remove the transmission fluid fill tube to bell housing nut.
  3. Position the transmission fill tube aside. The tube does not require removal from the transmission.
  4. Remove the 3 turbocharger heat shield bolts.
  5. Remove the turbocharger heat shield.
  6. Remove the 3 turbocharger exhaust heat shield bolts.
  7. Remove the turbocharger exhaust heat shield.
  8. Remove the turbocharger exhaust pipe to right exhaust pipe bracket bolt.
  9. Loosen the turbocharger exhaust pipe clamp.
  10. Loosen the turbocharger exhaust pipe to catalytic converter pipe clamp. Position the clamp onto the catalytic converter pipe.
  11. Remove the turbocharger exhaust pipe.
  1. Position the turbocharger exhaust pipe.
  2. Tighten the turbocharger exhaust pipe clamp. Tighten: Tighten the turbocharger exhaust pipe clamp to 15 N.m (11 lb ft).
  3. Position the turbocharger exhaust pipe to catalytic converter pipe clamp. Tighten: Tighten the turbocharger exhaust pipe to catalytic converter pipe clamp to 40 N.m (30 lb ft).
  4. Install the turbocharger exhaust pipe to right exhaust pipe bracket bolt. Tighten: Tighten the turbocharger exhaust pipe to right exhaust pipe bracket bolt to 34 N.m (25 lb ft).
  5. Position the turbocharger exhaust heat shield.
  6. Install the 3 turbocharger exhaust heat shield bolts. Tighten: Tighten the turbocharger exhaust heat shield bolts to 8 N.m (71 lb in).
  7. Install the turbocharger heat shield.
  8. Install the 3 turbocharger heat shield bolts. Tighten: Tighten the turbocharger heat shield bolts to 9 N.m (80 lb in).
  9. Position the transmission fill tube and install the transmission fill tube to bell housing nut. Tighten: Tighten the transmission fill tube to bell housing nut to 18 N.m (13 lb ft).
  10. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  2. Drain the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (Vac N Fill)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-vac) .
  3. Remove the exhaust gas recirculation (EGR) cooler pipe bolt.
  4. Remove the transmission fluid fill tube to bell housing nut.
  5. Position the transmission fill tube aside. The tube does not require removal from the transmission.
  6. Reposition the EGR cooler pipe clamp (1) and remove the EGR cooler pipe hose from the EGR cooler tube.
  7. Reposition the EGR cooler pipe (4) out of the way.
  8. Remove the EGR valve adapter pipe bracket bolts (1).
  9. Remove the EGR valve adapter pipe bracket (2) and turbocharger heat shield (3).
  10. Remove the turbocharger exhaust heat shield bolts.
  11. Remove the turbocharger exhaust heat shield.
  12. Loosen the turbocharger exhaust pipe clamp (1).
  13. Loosen the turbocharger exhaust pipe to catalytic converter pipe clamp (1). Position the clamp onto the catalytic converter pipe.
  14. Remove the turbocharger exhaust pipe to right exhaust pipe bracket bolt (2).
  15. Remove the turbocharger exhaust pipe and clamp (1).
  1. Place the turbocharger exhaust pipe into position and install the exhaust pipe clamp (1). Tighten the clamp until snug.
  2. Install the turbocharger exhaust pipe to right exhaust pipe bracket bolt (2). Tighten: Tighten the bolt to 34 N.m (25 lb ft).
  3. Tighten the turbocharger exhaust pipe clamp (1). Tighten: Tighten the clamp to 15 N.m (11 lb ft).
  4. Position the turbocharger exhaust pipe to catalytic converter pipe clamp (1). Tighten: Tighten the clamp to 40 N.m (30 lb ft).
  5. Position the turbocharger exhaust heat shield.
  6. Install the turbocharger exhaust heat shield bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  7. Install the turbocharger heat shield (3) and EGR valve adapter pipe bracket (2).
  8. Install the EGR valve adapter pipe bracket bolts (1).
  9. Position the EGR cooler pipe (4).
  10. Install the EGR cooler pipe hose to the EGR cooler tube and Reposition the EGR cooler pipe clamp (1).
  11. Position the transmission fill tube.
  12. Install the transmission fluid fill tube to bell housing nut. Tighten: Tighten the nut to 18 N.m (13 lb ft).
  13. Install the EGR cooler pipe bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  14. Fill the cooling system. Refer to «Draining and Filling Cooling System (Static Fill)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (Vac N Fill)»(/chevrolet/chevy-express-h1500/2003-2012/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-vac) .
  15. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  2. Remove the left exhaust pipe heat shield bolts.
  3. Remove the heat shield.
  4. Remove the exhaust pipe bolts in the proper sequence.
  5. Remove the exhaust pipe and gaskets.
  6. 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 engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  2. Remove the left exhaust pipe heat shield bolts (1).
  3. Remove the heat shield.
  4. Remove the exhaust pipe bolts in the proper sequence.
  5. Remove the exhaust pipe and gaskets.
  6. 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. Position the heat shield to the exhaust pipe.
  7. Install the exhaust pipe heat shield bolts (1). Tighten: Tighten the bolts to 8 N.m (71 lb in).
  8. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/exteriorinterior-trim/#interior-trim-and-paneling) .
  1. Remove the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Turbocharger Exhaust Pipe Replacement (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  2. Remove the exhaust right pipe bolts in the proper sequence.
  3. Remove the right exhaust pipe, bracket and gaskets.
  4. Discard the gaskets.
  1. Position the right 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 right 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 right exhaust pipe bolts in the proper sequence. Tighten: Tighten the bolts to 53 N.m (39 lb ft).
  6. Install the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Turbocharger Exhaust Pipe Replacement (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  1. Remove the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Turbocharger Exhaust Pipe Replacement (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  2. Remove the exhaust right pipe bolts in the proper sequence.
  3. Remove the right exhaust pipe, bracket and gaskets.
  4. Discard the gaskets.
  1. Position the right 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 right 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 right exhaust pipe bolts in the proper sequence. Tighten: Tighten the bolts to 53 N.m (39 lb ft).
  6. Install the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L (LBZ/LLY))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) or «Turbocharger Exhaust Pipe Replacement (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  2. Disconnect the oxygen sensors.
  3. Remove the exhaust hanger bolts and hanger from the vehicle.
  4. Remove the nuts retaining the exhaust pipe flange to the catalytic converter pipe.
  5. Remove the nuts retaining the exhaust pipe flange to the muffler.
  6. Remove the exhaust pipe.
  7. Remove the flange gasket.
  1. Remove the oxygen sensors and install into the new exhaust pipe. Tighten: Tighten the sensors to 42 N.m (31 lb ft).
  2. Install new gaskets to the muffler flange and the catalytic converter pipe flange.
  3. Install the exhaust pipe.
  4. Install the nuts for the catalytic converter pipe to the exhaust pipe. Tighten: Tighten the flange nuts to 48 N.m (35 lb ft).
  5. Install the nuts for the muffler to the exhaust pipe. Tighten: Tighten the nuts to 48 N.m (35 lb ft).
  6. Connect the oxygen sensor connectors.
  7. Install the exhaust hanger and bolts. Tighten: Tighten the bolts to 17 N.m (13 lb ft).
  8. Verify the exhaust system for proper clearance and the alignment of all components.
  9. Lower the vehicle.
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  2. Disconnect the oxygen sensor connectors.
  3. Remove the exhaust hanger bolts and hanger from the vehicle.
  4. Remove the nuts retaining the exhaust pipe flange to the catalytic converter pipe.
  5. Loosen the nut retaining the exhaust pipe clamp to the muffler.
  6. Remove the exhaust pipe and flange gasket.
  1. Remove the oxygen sensors and install into new exhaust pipe. Tighten: Tighten the sensors to 42 N.m (31 lb ft).
  2. Install new gasket to the catalytic converter pipe flange.
  3. Install the exhaust pipe to the vehicle.
  4. Install the nuts for the catalytic converter pipe to exhaust pipe. Tighten: Tighten the flange nuts to 48 N.m (35 lb ft).
  5. Tighten the exhaust pipe clamp nut. Tighten: Tighten the nut to 54 N.m (40 lb ft).
  6. Verify the exhaust system for proper clearance and the alignment of all components.
  7. Install the exhaust hanger and bolts. Tighten: Tighten the bolts to 17 N.m (13 lb ft).
  8. Lower the vehicle.
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  2. Disconnect the heated oxygen sensor (HO2S) electrical connections from catalytic converter pipe.
  3. Remove the exhaust hanger bolts and hanger from the transmission.
  4. Remove the nuts and the seals retaining the catalytic converter pipe to the exhaust manifolds.
  5. Remove the flange nuts from the catalytic pipe to the muffler.
  6. Remove the catalytic converter from the vehicle.
  7. Remove the oxygen sensors as necessary. Refer to «Heated Oxygen Sensor Replacement - Bank 1 Sensor 1»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-43l-introduction-2-of-2__heated-oxygen-sensor-replacement-bank) .
  1. Install the oxygen sensors as necessary. Refer to «Heated Oxygen Sensor Replacement - Bank 1 Sensor 1»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-43l-introduction-2-of-2__heated-oxygen-sensor-replacement-bank) .
  2. Position the catalytic pipe to the vehicle.
  3. Install the retaining nuts to the front of the muffler. Do not tighten the nuts.
  4. Install the new seals, the nuts and the exhaust pipe flange to exhaust manifold. Tighten: Tighten the exhaust pipe flange to exhaust manifold nuts to 65 N.m (48 lb ft). Tighten the catalytic converter to muffler retaining nuts to 48 N.m (35 lb ft).
  5. Connect the HO2S electrical connections.
  6. Install the exhaust hanger and bolts to the transmission. Tighten: Tighten the bolts to 17 N.m (13 lb ft).
  7. Verify the exhaust system for proper clearance and the alignment of all components.
  8. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/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. Remove the catalytic converter to muffler nuts (3).
  8. Loosen the exhaust pipe clamp.
  9. Slide the exhaust pipe clamp up onto the exhaust pipe adapter.
  10. Slide the catalytic converter hanger out of the exhaust pipe hanger bracket and remove the catalytic converter.
  1. Install the catalytic converter.
  2. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation.
  3. Slide the catalytic converter hanger into the exhaust pipe hanger bracket.
  4. Install the catalytic converter to muffler nuts (3) until snug.
  5. Slide the exhaust pipe clamp down and around the pipe connection.
  6. Tighten the exhaust pipe clamp and catalytic converter nuts. Tighten: Tighten the clamp to 40 N.m (30 lb ft). Tighten the nuts to 40 N.m (30 lb ft).
  7. Lower the transmission onto the transmission support.
  8. Install the transmission mount to transmission support nuts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  9. Remove the support from the transmission.
  10. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/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. Remove the catalytic converter to particulate filter nuts (3).
  8. Loosen the exhaust pipe clamp (1).
  9. Slide the exhaust pipe clamp up onto the exhaust pipe adapter.
  10. Slide the catalytic converter hanger out of the exhaust pipe hanger bracket and remove the catalytic converter.
  1. Install the catalytic converter.
  2. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation.
  3. Slide the catalytic converter hanger into the exhaust pipe hanger bracket.
  4. Install the catalytic converter to particulate filter nuts (3) until snug.
  5. Slide the exhaust pipe clamp (1) down and around the pipe connection.
  6. Tighten the exhaust pipe clamp and catalytic converter nuts. Tighten: Tighten the clamp to 40 N.m (30 lb ft). Tighten the nuts to 40 N.m (30 lb ft).
  7. Lower the transmission onto the transmission support.
  8. Install the transmission mount to transmission support nuts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  9. Remove the support from the transmission.
  10. Lower the vehicle.

Diagnostic Instructions

  1. Perform the «Diagnostic System Check - Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-system-check-vehicle) prior to using this diagnostic procedure.
  2. Review «Strategy Based Diagnosis»(/chevrolet/chevy-express-h1500/2003-2012/remont/oem-general-information/#vehicle-diagnostic-information__strategy-based-diagnosis) for an overview of the diagnostic approach.
  3. «Diagnostic Procedure Instructions»(/chevrolet/chevy-express-h1500/2003-2012/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-procedure-instructions) provide an overview of each diagnostic category.
CAUTIONTailpipe outlet exhaust temperature will be greater than 300°C (572°F) during service regeneration. To help prevent personal injury or property damage from fire or burns, perform the following: Do not connect any shop exhaust removal hoses to the vehicle's tailpipe. Park the vehicle outdoors and keep people, other vehicles, and combustible material away during service regeneration. Do not leave the vehicle unattended.
CAUTIONTo avoid extremely elevated exhaust temperatures, inspect and remove any debris or mud build up at the exhaust cooler located at the tailpipe.

Note. Due to the elevated engine temperatures created while performing this procedure it is imperative to keep the front of vehicle in an open environment, away from any walls or buildings, this will ensure proper airflow across the radiator.

Conditions for Running

The following conditions must be met in order to enable DPF Service Regeneration

  1. There are no active DTCs displayed.
  2. The battery voltage is greater than 10 volts.
  3. The engine speed is between 600-1,250 RPM.
  4. The exhaust gas temperature (EGT) sensors 1 and 2 are less than 400°C (752°F).
  5. The engine coolant temperature (ECT) sensor 1 is between 70-115°C (158-239°F).
  6. The brake pedal and accelerator pedal are in the released position.
  7. The transmission is in park or neutral.

Test Procedure

  1. Review the DTC information with a scan tool. Repair any codes before proceeding with DPF Service Regeneration.
  2. Check the following fluid levels before and after this procedure: Engine oil Engine coolant Power steering Transmission Fuel level should be over 15 percent to ensure a successful regeneration.
  3. Park the vehicle outside the facility and away from any obstacles.
  4. Place the transmission in Park and apply the parking brake.
  5. Raise the hood.
  6. Select DPF Service Regeneration in the Output Controls menu and follow the instruction on the scan tool.
  7. Command the DPF Service Regeneration with the scan tool.
  8. The DPF Service Regeneration will take approximately 35 minutes consisting of the following: 8 minutes for the exhaust system to warm up, with the engine speed slowly increasing to 1,600 RPM, then 2,200 RPM and finally 2,500 RPM 20 minutes for the DPF to regenerate at 2,500 RPM 3 minutes for the exhaust system to cool down with the engine speed will slowly returning to 1,400 RPM 3 minutes at 800 RPM, then idle speed of 680 RPM
  9. The DPF Service Regeneration can be terminated by performing any of the following actions: Applying the brake pedal Applying the accelerator pedal Selecting Drive or Reverse Commanding DPF Service Regeneration OFF using the scan tool or disconnecting the scan tool from the vehicle The DPF Service Regeneration will be automatically terminated if certain DTCs are set or if the DPF or ECT temperatures exceed a calibrated threshold.
  10. After the service regeneration completes, allow the vehicle to idle for an additional 2 minutes while monitoring the scan tool DTC information. There should be no additional DTCs setting. If service regeneration aborts, correct the condition for running service regeneration and then reset. If service regeneration fails, repair the vehicle for the condition indicated by the failure message on the scan tool. Refer to the Service Regeneration Fault Table below.
  11. Operate the vehicle within the following conditions: The vehicle speed is greater than 40 km/h (25 mph). The engine load is greater that 25 percent. Engine Run Time Since Last DPF Regeneration is less than 10 minutes. Distance Since Last DPF Regeneration is less than 30 km (18.6 miles). The Soot Mass is less than 40 grams. DTC P2002 runs one time after the above conditions are met. Verify that P2002 has run and passed.
  12. Verify that the scan tool DPF Soot Mass parameter is less than 10 grams.

Service Regeneration Unsuccessful

  1. Observe the scan tool for DTCs. If any DTCs are displayed, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-trouble-code-dtc-list) .
  2. DPF Regen Inhibit Reason parameter, will display a reason for not enabling DPF Service Regeneration. Refer to the parameters that are displayed.
  3. DPF Regeneration Status parameter will display Active or Not Required depending on the current commanded state of regeneration.
  4. DPF Soot Mass parameter, will display greater than 10 grams, indicating excessive particulate matter is still present in the filter, another Service Regeneration may be necessary.
DPF Regeneration ParametersSuccessful RegenerationUnsuccessful Regeneration
DPF Regeneration StatusNot RequiredActive or Required
DPF Regeneration ReasonNoneFuel Used Engine Run Time Distance Traveled DPF Pressure Soot Mass Calculated Soot
DPF Regeneration Inhibit ReasonNoneVaries
DPF Soot MassLess than 10 gramsGreater than 10 grams

Service Regeneration Status Fault Table

DPF Regeneration Enable

IMPORTANTThe DPF Regeneration Enable is required when specific service procedures have been performed. Do not perform a DPF Regeneration Enable unless instructed to in the Repair Instruction section of the service procedure. After the system repair perform the following to avoid possible damage to the DPF.
  1. Ignition ON, clear all DTCs with a scan tool.
  2. Select DPF Regeneration Enable within the Special Function menu.
  3. Select ON. The selection can be confirmed by the DPF Regeneration Reason parameter indicating Device Control.
  4. Exit the Special Function Menu. The scan tool can now be removed.

The vehicle will perform an active Regeneration as soon as the engine running conditions are met.

  1. Remove the tail pipe. Refer to «Tail Pipe Replacement (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
  2. Remove the exhaust temperature sensors. Refer to «Exhaust Temperature Sensor Replacement - Position 1»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) and «Exhaust Temperature Sensor Replacement - Position 2»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
  3. Remove the exhaust pressure differential sensor pipe. Refer to «Exhaust Pressure Differential Sensor Pipe Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
  4. Remove the catalytic converter to particulate filter nuts.
  5. Remove the exhaust particulate filter.
  6. Remove and discard the exhaust particulate filter gasket.
  1. Install a NEW gasket onto the catalytic converter studs.
  2. Install the exhaust particulate filter.
  3. Install the catalytic converter to particulate filter nuts. Tighten: Tighten the nuts to 40 N.m (30 lb ft).
  4. Install the exhaust pressure differential sensor pipe. Refer to «Exhaust Pressure Differential Sensor Pipe Replacement»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
  5. Install the exhaust temperature sensors. Refer to «Exhaust Temperature Sensor Replacement - Position 1»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) and «Exhaust Temperature Sensor Replacement - Position 2»(/chevrolet/chevy-express-h1500/2003-2012/remont/testing-diagnostics/#engine-control-system-fuel-system-66l-lmm-introduction-2-of-2) .
  6. Install the tail pipe. Refer to «Tail Pipe Replacement (6.6L (LMM))»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system) .
CAUTIONRefer to PROTECTIVE GOGGLES AND GLOVE CAUTION .
CAUTIONRefer to EXHAUST SERVICE CAUTION
IMPORTANTThe muffler is serviced as one complete unit with an exhaust pipe and tail pipe. Some variations of vehicles may have an aftermarket tail pipe added. When the vehicle is raised on the hoist it must be raised by the frame to allow the rear axle to be lowered.
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  2. If equipped with 4.3L engine with a single catalytic converter pipe, remove the nuts retaining the catalytic converter pipe from the muffler flange.
  3. If equipped with a 4.8L/5.3L/6.0L engine with dual catalytic converter pipes, loosen the clamp for the right catalytic converter.
  4. Remove the nuts retaining the left catalytic converter to the muffler flange.
  5. Remove the muffler assembly hanger pins from the exhaust hanger insulators. Due to the weight of the exhaust system it may take 2 people.
  6. Remove the muffler assembly by lifting over the rear axle and remove towards the front of the vehicle.
  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. 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. 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.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/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. Loosen the exhaust pipe clamp.
  11. With the aid of an assistant, support the exhaust muffler.
  12. Remove the exhaust muffler nuts.
  13. With the aid of an assistant, support the exhaust muffler.
  14. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the catalytic converter.
  15. Remove the insulators from the muffler hangers.
  16. Remove the exhaust manifold pipe gasket, if necessary.
  17. Remove the insulators from the frame hangers.
  18. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the exhaust muffler pipe.
  19. Remove the exhaust muffler gasket, if necessary.
  20. Remove the insulators from the muffler hangers.
  21. 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. Install the insulators to the muffler hangers.
  2. Install a new exhaust muffler gasket.
  3. With the aid of an assistant, slide the muffler forward in order to install the muffler to the exhaust muffler pipe.
  4. Install the insulators to the frame hangers.
  5. Install a new exhaust manifold pipe gasket.
  6. With the aid of an assistant, slide the muffler forward in order to install the muffler to the catalytic converter.
  7. Install the insulators to the frame hangers.
  8. Install the exhaust muffler nuts. Tighten: Tighten the nuts to 40 N.m (30 lb ft).
  9. Install the exhaust muffler nuts.
  10. 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).
  11. Raise the rear axle using the adjustable jack stands, if necessary.
  12. Install the rear shock absorbers lower bolts and nuts, if necessary. Tighten: Tighten the bolts to 95 N.m (70 lb ft).
  13. If equipped with a 10.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  14. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  15. If equipped with a 8.6 or 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  16. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  17. Remove the adjustable jack stands from under the rear axle, if necessary.
  18. Install the spare tire, if necessary.
  19. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the spare tire, if necessary.
  3. Remove the exhaust particulate filter to tail pipe nuts.
  4. With the aid of an assistant, separate the tail pipe hangers from the insulators and remove the exhaust tail pipe.
  1. With the aid of an assistant, install the exhaust tail pipe and install the tail pipe hangers to the insulators.
  2. Install the exhaust particulate filter to tail pipe nuts. Tighten: Tighten the nuts to 40 N.m (30 lb ft).
  3. Install the spare tire, if necessary.
  4. lower the vehicle.

Tools Required

J 34940 Rivet Gun. See Special Tools .

  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  2. Using a 1/4 inch (6 mm) drill bit, remove the rivets from the heat shields, as necessary.
  3. Remove the exhaust tailpipe heat shield from the vehicle.
  4. Remove the muffler heat shield.
  5. Remove the front exhaust pipe heat shield.
  1. Install the front exhaust pipe heat shield on the vehicle.
  2. Install the rivets on the heat shield using the J 34940 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system__special-tools) .
  3. Install the muffler heat shield on the vehicle.
  4. Install the rivets on the heat shield using the J 34940 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system__special-tools) .
  5. Install the exhaust tailpipe heat shield on the vehicle.
  6. Install the rivets on the heat shield using the J 34940 . See «Special Tools»(/chevrolet/chevy-express-h1500/2003-2012/remont/exhaust/#engine-exhaust-system__special-tools) .
  7. Lower the vehicle.
  1. Raise and suitably support the vehicle with safety stands. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .
  2. Remove the exhaust system, as necessary.
  3. Remove the bolts retaining the heat shield.
  4. Remove the heat shield.
  1. Install the heat shield.
  2. Install the heat shield bolts. Tighten: Tighten the heat shield retainer bolt to 12 N.m (106 lb in).
  3. Install the exhaust system, as necessary.
  4. Remove the safety stands and lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-h1500/2003-2012/remont/hoistjack/#general-information) .

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 34940 Rivet Gun

Scheme 3

Scheme 3: Special Tools
Scheme 3: Special Tools

See also:
• Strategy Based Diagnosis
• Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
• Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
• Lifting and Jacking the Vehicle
• Engine Cover Replacement
• Fastener Notice
• Tire and Wheel Removal and Installation
• Starter Motor Replacement (4.3L)
• Spark Plug Wire Replacement
• Oil Level Indicator and Tube Removal
• Draining and Filling Cooling System (Static Fill)
• Draining and Filling Cooling System (Vac N Fill)
• Diagnostic System Check - Vehicle
• Diagnostic Procedure Instructions
• Road Test Caution
• Diagnostic Trouble Code (DTC) List - Vehicle
• Exhaust Temperature Sensor Replacement - Position 1
• Symptoms - Engine Exhaust
• Exhaust System Description
• Restricted Exhaust
• Exhaust Leakage
• Exhaust Noise
• Fastener Tightening Specifications
• Special Tools