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Engine Exhaust System Chevrolet Express G2500

Exhaust 10 illustrations ~4311 words

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
3-Way Catalytic Converter Nuts to Exhaust Manifold Studs63 N.m48 lb ft
3-Way Catalytic Converter to Muffler Nuts48 N.m35 lb ft
Catalytic Converter to Exhaust Manifold Nut (4.3L)50 N.m37 lb ft
Catalytic Converter Hanger Bracket to Transmission Bolt (6.6L)58 N.m43 lb ft
Catalytic Converter to Muffler Clamp (4.8L, 5.3L, 6.0L)54 N.m40 lb ft
Catalytic Converter to Muffler Nut (4.8L, 5.3L, 6.0L)48 N.m35 lb ft
Catalytic Converter Nut (6.6L)40 N.m30 lb ft
Catalytic Converter to Particulate Filter Nut (6.6L)45 N.m33 lb ft
Catalytic Converter Pipe to Exhaust Pipe Nut (6.0L)48 N.m35 lb ft
Exhaust Hanger Bolt (4.8L, 5.3L, 6.0L)17 N.m13 lb ft
Exhaust Hanger to Transmission Bolt (4.3L)50 N.m37 lb ft
Exhaust Manifold Bolt/Stud (4.3L)
First Pass15 N.m11 lb ft
Final Pass30 N.m22 lb ft
Exhaust Manifold Bolt (4.8L, 5.3L, and 6.0L)
First Pass15 N.m11 lb ft
Final Pass20 N.m15 lb ft
Exhaust Manifold Bolt/Nut (6.6L)57 N.m42 lb ft
Exhaust Manifold Outlet Pipe Bolt/Nut (6.6L)53 N.m39 lb ft
Exhaust Pipe Clamp (6.0L)54 N.m40 lb ft
Exhaust Pipe Flange to Exhaust Manifold Nut (4.8L, 5.3L)65 N.m48 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
Exhaust Manifold Pipe Studs (4.8L, 5.3L, and 6.0L)20 N.m15 lb ft
Exhaust Temperature Sensor. (6.6L)45 N.m33 lb ft
Heat Shield Bolt9 N.m80 lb in
Indirect Injector Nozzle (6.6L)45 N.m33 lb ft
Muffler to Catalytic Converter Nut (4.3L)48 N.m35 lb ft
Muffler to Exhaust Pipe Nut (6.0L)48 N.m35 lb ft
Nitrogen Oxide Sensor (6.6L)45 N.m33 lb ft
Turbocharger Exhaust Heat Shield Bolt (6.6L)10 N.m89 lb in
Turbocharger Exhaust Pipe to Catalytic Converter Clamp (6.6L)15 N.m11 lb ft
Turbocharger Exhaust Pipe Clamp (6.6L)15 N.m11 lb ft
Turbocharger Exhaust Pipe Bracket Bolt (6.6L)34 N.m25 lb ft
Turbocharger Heat Shield Bolt (6.6L)10 N.m89 lb in

Fastener Tightening Specifications

Adhesives, Fluids, Lubricants, and Sealers

ApplicationType of MaterialGM Part Number
United StatesCanada
Anti-SeizeLubricant8886247788862478

Adhesives, Fluids, Lubricants, and Sealers

Symptoms - Engine Exhaust

  1. Review the exhaust system description in order to familiarize yourself with the exhaust system components and the intended function of the components. Refer to «Exhaust System Description»(/chevrolet/express-g2500/2013-2013/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/express-g2500/2013-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) .

Visual/Physical Inspection

  1. Inspect for aftermarket or non-OEM devices such as, but not limited to; tailpipe extensions, headers, and exhaust cutouts. Any aftermarket exhaust system devices 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/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system)
  2. Poor acceleration Refer to «Restricted Exhaust»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system)
  3. Poor fuel economy Refer to «Restricted Exhaust»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system)
  4. Excessive smoke diesel Refer to «Restricted Exhaust»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system)
  5. Exhaust hissing noise Refer to «Exhaust Leakage»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system__exhaust-leakage)
  6. Exhaust popping noise Refer to «Exhaust Leakage»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system__exhaust-leakage)
  7. Exhaust rattle noise Refer to «Exhaust Noise»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system__exhaust-noise)
  8. Loud exhaust noise Refer to «Exhaust Noise»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system__exhaust-noise)
  9. Exhaust buzz, groan, hum noise Refer to «Exhaust Noise»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system__exhaust-noise)

Diagnostic Aids

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

Note. Do not replace a restricted particulate filter. Repair the engine condition that clogged the particulate filter, and then attempt the perform a service regeneration. Refer to Diesel Particulate Filter (DPF) Service Regeneration .

If the vehicle is equipped with a 6.6L diesel engine do not perform this diagnostic. The exhaust system does not have a location for installing the J 35314-A exhaust back pressure gauge. 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 a 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 exhaust back pressure gauge. Removing the heated oxygen sensor (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 the 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 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, or 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 engines. Install the J 35314-A exhaust back pressure gauge in place of the HO2S. Start the engine. Increase and monitor the engine speed at 2000 RPM. Observe the exhaust system back pressure reading on the gauge. 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 exhaust back pressure gauge. Re-install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 , or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 , for the 4.3L engine, or 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 engines. Remove the post-catalyst HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 , or Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 , for the 4.3L engine, or 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 engines. Install the J 35314-A exhaust back pressure gauge in place of the post-catalyst HO2S. Start the engine. Increase and monitor the engine speed at 2000 RPM. Observe the exhaust system back pressure reading on the gauge. 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 (L20,LMF) , Catalytic Converter Replacement (V6) , Catalytic Converter Replacement (LGH) , Catalytic Converter Replacement (LC8,L96) . Did you find and correct the condition?Go to Step 8
8Remove the J 35314-A exhaust back pressure gauge. Re-install the post-catalyst HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 , or Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 , for the 4.3L engine, or 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 engines. 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
WARNING: 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 (V6) , Exhaust Manifold Replacement - Left Side (V8) , Exhaust Manifold Replacement - Left Side (Diesel) , or Exhaust Manifold Replacement - Right Side (V6) , Exhaust Manifold Replacement - Right Side (Diesel) , Exhaust Manifold Replacement - Right Side (V8) .
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.Refer to Exhaust Muffler Replacement (L20,LMF,LU3) , Exhaust Muffler Replacement (LC8,L96)
WARNING
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
WARNING: 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 Exhaust Muffler Replacement (L20,LMF,LU3) , Exhaust Muffler Replacement (LC8,L96) .
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 (L20,LMF) , Catalytic Converter Replacement (V6) , Catalytic Converter Replacement (LGH) , Catalytic Converter Replacement (LC8,L96) Exhaust Muffler Replacement (L20,LMF,LU3) , Exhaust Muffler Replacement (LC8,L96)
WARNING
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. Remove the left front wheel and tire. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
  2. Remove the left wheelhouse splash shield. Refer to «Wheelhouse Splash Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  3. Remove the catalytic converter assembly. Refer to «Catalytic Converter Replacement (V6)»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system) .
  4. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
  5. Remove the exhaust manifold bolts (3) and stud (4).
  6. Remove the exhaust manifold (2) .
  7. Remove and discard the exhaust manifold gaskets (1).

Installation Procedure

Note. To aid in installing the exhaust manifold to the engine, the bolt holes on the NEW exhaust manifold gaskets have tabs that will hold the gasket and the bolts in place.

  1. Install the exhaust manifold bolts (3) and stud (4) to the manifold.
  2. Install NEW exhaust manifold gaskets (1) onto the bolt and stud.
  3. Position and install the exhaust manifold (2) to the cylinder head. Tighten the bolts/stud a first pass to 15 N.m (11 lb ft). Tighten the bolts/stud a final pass to 30 N.m (22 lb ft).
  4. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
  5. Install the catalytic converter assembly. Refer to «Catalytic Converter Replacement (V6)»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system) .
  6. Install the left wheelhouse splash shield. Refer to «Wheelhouse Splash Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  7. Install the left front wheel and tire. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
  2. Separate the catalytic converter from the exhaust manifold. Refer to «Catalytic Converter Replacement (L20,LMF)»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system) , «Catalytic Converter Replacement (LC8,L96)»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system) .
  3. Lower the vehicle.
  4. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g2500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
  5. Disconnect the exhaust gas recirculation (EGR) pipe from the exhaust manifold, if equipped.
  6. Remove the spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
  7. Remove the exhaust manifold bolts and remove the exhaust manifold from the vehicle.
  8. Discard the gasket and the exhaust manifold to catalytic converter seal.
  9. Remove the heat shield (603) and bolts (604) from the manifold (600), as required.
  10. Remove the studs (605), as required.
  1. Install the heat shield (603) and bolts (604)and tighten to 9 N.m (80 lb in).
  2. Install the exhaust pipe studs (605) and tighten to 20 N.m (15 lb ft).
  3. 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. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-48l-l20-53l-lmf-or-60l-l96-lc8-specifications__adhesives-fluids-lubricants-and-sealers) .
  4. Position the exhaust manifold gasket to the manifold with two manifold bolts.
  5. Install the exhaust manifold to the cylinder head. Tighten the manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the manifold bolts a final pass to 20 N.m (15 lb ft). Tighten the manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
  6. Using a flat punch, bend over the exposed edge of the manifold gasket at the rear of the cylinder head.
  7. Connect the EGR pipe to the manifold, if equipped.
  8. Install the spark plug wires to the spark plugs. Refer to «Spark Plug Wire Replacement»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
  9. Using a NEW seal, install the catalytic converter to the exhaust manifold. Refer to «Catalytic Converter Replacement (L20,LMF)»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system) , «Catalytic Converter Replacement (LC8,L96)»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system) .
  10. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g2500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
  11. Inspect for exhaust leaks.

Scheme 1

Scheme 1: Exhaust Manifold Replacement - Left Side (Diesel)
Scheme 1: Exhaust Manifold Replacement - Left Side (Diesel)
CalloutComponent Name
Preliminary Procedures Remove the left exhaust manifold outlet pipe. Refer to Exhaust Manifold Outlet Pipe Replacement - Left Side (LGH) . Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Exhaust Manifold Nut (Qty: 2) CAUTION: Refer to Fastener Caution . TIP: Torque the exhaust manifold nuts in the sequence shown in the graphic. Tighten 57 N.m (42 lb ft)
2Exhaust Manifold Bolt (Qty: 6) TIP: Torque the exhaust manifold bolts in the sequence shown in the graphic. Tighten 57 N.m (42 lb ft)
3Left Side Exhaust Manifold Procedure Transfer the exhaust manifold heat shield. Replace or transfer the exhaust manifold gasket as needed.
CAUTION
Refer to Fastener Caution .

Exhaust Manifold Replacement - Left Side (Diesel)

  1. Remove the right front wheel and tire. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
  2. Remove the right wheelhouse splash shield. Refer to «Wheelhouse Splash Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  3. Remove the catalytic converter assembly. Refer to «Catalytic Converter Replacement (V6)»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system) .
  4. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
  5. Remove the exhaust manifold bolts (3).
  6. Remove the exhaust manifold (1) .
  7. Remove and discard the exhaust manifold gaskets (2).

Note. To aid in installing the exhaust manifold to the engine, the bolt holes on the NEW exhaust manifold gaskets have tabs that will hold the gasket and the bolts in place.

  1. Install the exhaust manifold bolts (3) to the manifold.
  2. Install NEW exhaust manifold gaskets (2) onto the bolt and stud.
  3. Position and install the exhaust manifold (1) to the cylinder head. Tighten the bolts a first pass to 15 N.m (11 lb ft). Tighten the bolts a final pass to 30 N.m (22 lb ft).
  4. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
  5. Install the catalytic converter assembly. Refer to «Catalytic Converter Replacement (V6)»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system) .
  6. Install the right wheelhouse splash shield. Refer to «Wheelhouse Splash Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  7. Install the right front wheel and tire. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
  2. Separate the catalytic converter from the exhaust manifold. Refer to «Catalytic Converter Replacement (L20,LMF)»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system) , «Catalytic Converter Replacement (LC8,L96)»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system) .
  3. Lower the vehicle.
  4. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g2500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
  5. Remove the oil level indicator tube. Refer to «Oil Level Indicator Tube Replacement»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions-on-vehicle) .
  6. Remove the spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
  7. Remove the exhaust manifold bolts and remove the exhaust manifold from the vehicle.
  8. Discard the exhaust manifold gasket and the exhaust manifold to catalytic converter seal.
  9. Remove the exhaust manifold studs.
  1. Install the exhaust manifold studs to the new manifold.
  2. Install the new exhaust manifold seal to the new manifold.
  3. Position the exhaust manifold to the cylinder head. Tighten the exhaust manifold bolts - First Pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts - Second Pass to 20 N.m (15 lb ft).
  4. Install the oil level indicator tube. Refer to «Oil Level Indicator Tube Replacement»(/chevrolet/express-g2500/2013-2013/remont/mechanical/#engine-mechanical-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions-on-vehicle) .
  5. Install the spark plug wires. Refer to «Spark Plug Wire Replacement»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
  6. Install the catalytic converter to the exhaust manifold. Refer to «Catalytic Converter Replacement (L20,LMF)»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system) , «Catalytic Converter Replacement (LC8,L96)»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system) .
  7. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g2500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
  8. Inspect for exhaust leaks.

Scheme 2

Scheme 2: Exhaust Manifold Replacement - Right Side (Diesel)
Scheme 2: Exhaust Manifold Replacement - Right Side (Diesel)
CalloutComponent Name
Preliminary Procedures Remove the right exhaust manifold outlet pipe. Refer to Exhaust Manifold Outlet Pipe Replacement - Right Side (LGH) . Remove the right front tire and wheel. Refer to Tire and Wheel Removal and Installation (6-Lug Wheel) , Tire and Wheel Removal and Installation (8-Lug Wheel) . Remove the right side wheelhouse splash shield. Refer to Wheelhouse Splash Shield Replacement .
1Exhaust Manifold Nut (Qty: 2) CAUTION: Refer to Fastener Caution . TIP: Torque the exhaust manifold nuts in the sequence shown in the graphic. Tighten 57 N.m (42 lb ft)
2Exhaust Manifold Bolt (Qty: 6) TIP: Torque the bolts in the sequence shown in the graphic. Tighten 57 N.m (42 lb ft)
3Right Side Exhaust Manifold Procedure Transfer the exhaust manifold gasket. Replace or transfer the exhaust manifold gasket as needed.
CAUTION
Refer to Fastener Caution .

Exhaust Manifold Replacement - Right Side (Diesel)

Scheme 3

Scheme 3: Turbocharger Exhaust Pipe Replacement (LGH)
Scheme 3: Turbocharger Exhaust Pipe Replacement (LGH)
CalloutComponent Name
WARNING: Refer to Exhaust Service Warning . Preliminary Procedures Remove the engine cover. Refer to Engine Cover Replacement . Remove the exhaust temperature sensor and set aside. Refer to Exhaust Temperature Sensor Replacement - Position 1 . Remove the indirect fuel injector and set aside. Refer to Indirect Fuel Injector Replacement . Remove the nitrogen oxide sensor and set aside. Refer to Nitrogen Oxide Sensor Replacement - Position 1 . Remove the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement .
1Exhaust Temperature Sensor Connector
2Turbocharger Exhaust Pipe Bolt CAUTION: Refer to Fastener Caution . Tighten 34 N.m (25 lb ft)
3Turbocharger Exhaust Pipe Clamp Tighten 15 N.m (11 lb ft)
4Turbocharger Exhaust Pipe TIP: If replacing turbocharger exhaust pipe, transfer the exhaust temperature sensor over to the new pipe.
WARNING
Refer to Exhaust Service Warning .
CAUTION
Refer to Fastener Caution .

Turbocharger Exhaust Pipe Replacement (LGH)

WARNINGRefer to Exhaust Service Warning .
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g2500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
  2. Remove the exhaust manifold outlet pipe heat shield. Refer to «Turbocharger Heat Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system)
  3. Remove the exhaust manifold outlet pipe bolts in the proper sequence.
  4. Remove the exhaust manifold outlet pipe bolts (1) and replace gaskets (2) with NEW gaskets.
  5. Remove the exhaust manifold outlet pipe (3).
  1. Position the exhaust manifold outlet pipe (8)
  2. Loosely install the exhaust manifold outlet pipe to turbocharger with the bolts (4) and a NEW gasket (6).Align the tab on the gasket (6) to face downward.
  3. Position the exhaust manifold outlet pipe (8) with a NEW gasket (5) to the exhaust manifold. Align the tab on the gasket (5) to face outward.
  4. Position the exhaust manifold outlet pipe (8) with a NEW gasket (7) to the EGR valve cooler.Align the tab on the gasket (7) to face upward.
  5. Loosley tighten the bolts(2) and nuts(1) to the EGR valve cooler.
  6. Loosley tighten the exhaust manifold outlet pipe bolts (3) and turbocharger bolts (4).
  7. Tighten the exhaust manifold outlet pipe bolts and nuts in the sequence shown to 53 N.m (39 lb ft).
  8. Install the exhaust manifold outlet pipe heat shield. Refer to «Exhaust Pipe Heat Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system)
  9. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g2500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling)
WARNINGRefer to Exhaust Service Warning .
  1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g2500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
  2. Remove the exhaust manifold outlet pipe heat shield. Refer to «Turbocharger Heat Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system)
  3. Remove the exhaust manifold outlet pipe bolts in the proper sequence.
  4. Remove the exhaust manifold outlet pipe bolts (1) and replace gaskets (2) with NEW gaskets.
  5. Remove the exhaust manifold outlet pipe (3).
  1. Position the exhaust manifold outlet pipe (3) with the NEW gaskets (2) to the turbocharger.Align the tab on the gasket at the turbocharger to face inward
  2. Loosely install the exhaust pipe to turbocharger bolts (1).
  3. Position the exhaust manifold outlet pipe with a NEW gasket to the turbocharger. Align the tab on the gasket to face downward.
  4. Position the exhaust manifold outlet pipe with a NEW gasket to the exhaust manifold.Align the tab on the gasket to face outward.
  5. Tighten the exhaust pipe bolts in the sequence shown to 53 N.m (39 lb ft).
  6. Install the exhaust manifold outlet pipe heat shield. Refer to «Exhaust Pipe Heat Shield Replacement»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system)
  7. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-g2500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling)
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
  2. Remove the heated oxygen sensors (HO2S). Refer to «Heated Oxygen Sensor Replacement - Bank 1 Sensor 1»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , , «Heated Oxygen Sensor Replacement - Bank 1 Sensor 2»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , , «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , , and «Heated Oxygen Sensor Replacement - Bank 2 Sensor 2»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
  3. Remove the exhaust hanger bolts and hanger from the transmission.
  4. Remove the catalytic converter to exhaust manifold nuts (1).
  5. Remove the muffler to catalytic converter nuts (1).
  6. Lower the catalytic converter (3) from the vehicle.
  7. Remove and discard the exhaust manifold seals (1 and 2).
  1. Install a NEW exhaust manifold seal (1) into the groove in the left catalytic converter.
  2. Install a NEW exhaust manifold seal (2) into the right manifold.
  3. Position the catalytic converter (3) to the exhaust manifolds.
  4. Install the catalytic converter to exhaust manifold nuts (1) and tighten to 50 N.m (37 lb ft).
  5. Install the muffler to catalytic converter nuts (1) and tighten to 48 N.m (35 lb ft).
  6. Install the exhaust hanger bolts and hanger to the transmission and tighten to 50 N.m (37 lb ft).
  7. Install the HO2S. Refer to «Heated Oxygen Sensor Replacement - Bank 1 Sensor 1»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , , «Heated Oxygen Sensor Replacement - Bank 1 Sensor 2»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , , «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , , and «Heated Oxygen Sensor Replacement - Bank 2 Sensor 2»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
WARNINGRefer to Exhaust Service Warning .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
  2. Disconnect the heated oxygen sensor (HO2S) electrical connectors from the main harness connectors.
  3. Remove the nuts (1) from the catalytic converter pipe to the exhaust manifolds.
  4. Remove the nuts from the catalytic converter pipe to the muffler.
  5. Remove the catalytic converter from the vehicle.
  6. Remove and discard the exhaust manifold seals.
  7. If replacing the catalytic converter pipe, remove the oxygen sensors as necessary. Refer to «Heated Oxygen Sensor Replacement - Bank 1 Sensor 1»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .

Note. A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensors are to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.

  1. If reusing the old HO2S sensors, coat the threads with special ant-seize compound. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system__adhesives-fluids-lubricants-and-sealers) .
  2. Install the oxygen sensors to the catalytic converter. Refer to «Heated Oxygen Sensor Replacement - Bank 1 Sensor 1»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
  3. Install NEW seals to the exhaust manifolds.
  4. Position the catalytic converter to the exhaust manifolds and the muffler.
  5. Install the catalytic converter to muffler nuts, but do not completely tighten.
  6. Install the catalytic converter nuts to the exhaust manifold studs and tighten to 65 N.m(48 lb ft).
  7. Tighten the catalytic converter to muffler nuts (1) to 48 N.m (35 lb ft).
  8. Connect the HO2S electrical connections to the main harness connectors.
  9. Lower the vehicle and inspect for exhaust leaks.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
  2. Disconnect the engine harness connector (1) and the emission reduction fluid injector connector (2), from the catalytic converter.
  3. Disconnect the exhaust temperature sensor-position 2 connector from the lower right side of the transmission.
  4. Remove the catalytic coverter to diesel particulate filter nuts (3)
  5. loosen the turbocharger exhaust pipe-to-catalytic converter clamp (1).
  6. Remove the catalytic converter hanger to transmission bolts (1).
  7. With the catalytic converter hanger attached, lower the catalytic converter (2).
  8. If replacing catalytic converter, transfer the hanger bracket and the exhaust temperature sensor.
  1. If replacing the catalytic converter, apply water based lubricant to the catalytic converter hanger bracket and slide the exhaust pipe hanger bracket into the catalytic converter hanger.
  2. Install a NEW catalytic converter to diesel particulate filter gasket.
  3. Position the catalytic converter to the diesel particulate filter, turbocharger exhaust pipe and the hanger bracket to transmission.
  4. Install the catalytic converter hanger to transmission bolts (1) and tighten to 58 N.m (43 lb ft).
  5. Install the catalytic converter to particulate filter nuts (3) until snug.
  6. Slide the exhaust pipe clamp (1) down and around the pipe connection.
  7. Tighten the exhaust pipe clamp and catalytic converter nuts. Tighten the clamp to 15 N.m (11 lb ft). Tighten the nuts to 34 N.m (25 lb ft).
  8. Connect the exhaust temperature sensor-position 2 connector (1), to the catalytic converter.
  9. Connect the emission reduction fluid injector connector (2) and the engine harness connector (1).
  10. Lower the vehicle.

Scheme 4

Scheme 4: Catalytic Converter Replacement (LC8,L96)
Scheme 4: Catalytic Converter Replacement (LC8,L96)
CalloutComponent Name
WARNING: Refer to Exhaust Service Warning . WARNING: Refer to Eye Protection Warning . Preliminary Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Catalytic Converter to Exhaust Manifold Fasteners (Qty: 6) CAUTION: Refer to Fastener Caution . Tighten 45 N.m (33 lb ft)
2Exhaust Manifold Seals NOTE: Replace with NEW seals.
3Exhaust Muffler Fasteners (Qty: 2) Tighten 45 N.m (33 lb ft)
4Exhaust Muffler Gasket NOTE: Replace with NEW gasket.
5Catalytic Converter
WARNING
Refer to Exhaust Service Warning .
WARNING
Refer to Eye Protection Warning .
CAUTION
Refer to Fastener Caution .
NOTE
Replace with NEW seals.
NOTE
Replace with NEW gasket.

Catalytic Converter Replacement (LC8,L96)

WARNINGRefer to Exhaust Service Warning .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
  2. Disconnect the heated oxygen sensor (HO2S) electrical connectors from the main harness connectors.
  3. Remove the nuts (1) from the catalytic converter pipe to the exhaust manifolds.
  4. Remove the nuts from the catalytic converter pipe to the muffler.
  5. Remove the catalytic converter from the vehicle.
  6. Remove and discard the exhaust manifold seals.
  7. If replacing the catalytic converter pipe, remove the oxygen sensors as necessary. Refer to «Heated Oxygen Sensor Replacement - Bank 1 Sensor 1»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .

Note. A special anti-seize compound is used on the heated oxygen sensor (HO2S) threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an engine and if for any reason the sensors are to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.

  1. If reusing the old HO2S sensors, coat the threads with special ant-seize compound. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-g2500/2013-2013/remont/exhaust/#engine-exhaust-system__adhesives-fluids-lubricants-and-sealers) .
  2. Install the oxygen sensors to the catalytic converter. Refer to «Heated Oxygen Sensor Replacement - Bank 1 Sensor 1»(/chevrolet/express-g2500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
  3. Install NEW seals to the exhaust manifolds.
  4. Position the catalytic converter to the exhaust manifolds and the muffler.
  5. Install the catalytic converter to muffler nuts, but do not completely tighten.
  6. Install the catalytic converter nuts (1) to the exhaust manifold studs and tighten to 65 N.m (48 lb ft).
  7. Tighten the catalytic converter to muffler nuts to 48 N.m (35 lb ft).
  8. Connect the HO2S electrical connections to the main harness connectors.
  9. Lower the vehicle and inspect for exhaust leaks.

Scheme 5

Scheme 5: Exhaust Particulate Filter Replacement (LGH)
Scheme 5: Exhaust Particulate Filter Replacement (LGH)
CalloutComponent Name
Preliminary Procedure Raise and support the vehicle. Refer to Battery Negative Cable Disconnection and Connection Remove the diesel particulate exhaust temperature sensors. Refer to Exhaust Temperature Sensor Replacement - Position 1 , , Exhaust Temperature Sensor Replacement - Position 2 , , Exhaust Temperature Sensor Replacement - Position 3 , and Exhaust Temperature Sensor Replacement - Position 4 . Remove the exhaust pressure differential sensor pipe. Refer to Exhaust Pressure Differential Sensor Pipe Replacement . Remove the nitrogen oxide - position 2 sensor. Refer to Nitrogen Oxide Sensor Replacement - Position 2
1Catalytic Converter Nut (Qty: 4) WARNING: Refer to Exhaust Service Warning . CAUTION: Refer to Fastener Caution . Tighten 45 N.m (33 lb ft)
2Gasket TIP: Replace with a NEW gasket and clean the gasket surfaces.
3Exhaust Hanger Isolators
4Diesel Particulate Filter (DPF) with Exhaust
WARNING
Refer to Exhaust Service Warning .
CAUTION
Refer to Fastener Caution .

Exhaust Particulate Filter Replacement (LGH)

Scheme 6

Scheme 6: Exhaust Particulate Filter Replacement (LGH-35 Series)
Scheme 6: Exhaust Particulate Filter Replacement (LGH-35 Series)
CalloutComponent Name
Preliminary Procedure Raise and support the vehicle. Refer to Battery Negative Cable Disconnection and Connection Remove the diesel particulate exhaust temperature sensors. Refer to Exhaust Temperature Sensor Replacement - Position 1 , , Exhaust Temperature Sensor Replacement - Position 2 , , Exhaust Temperature Sensor Replacement - Position 3 , and Exhaust Temperature Sensor Replacement - Position 4 . Remove the exhaust pressure differential sensor pipe. Refer to Exhaust Pressure Differential Sensor Pipe Replacement . Remove the nitrogen oxide - position 2 sensor. Refer to Nitrogen Oxide Sensor Replacement - Position 2
1Catalytic Converter Nut (Qty: 4) WARNING: Refer to Exhaust Service Warning . CAUTION: Refer to Fastener Caution Tighten 45 N.m (33 lb ft)
2Gasket TIP: Replace with a NEW gasket and clean the gasket surfaces.
3Exhaust Hanger Isolators
4Diesel Particulate Filter (DPF) with Exhaust
WARNING
Refer to Exhaust Service Warning .
CAUTION
Refer to Fastener Caution

Exhaust Particulate Filter Replacement (LGH-35 Series)

WARNINGRefer to Exhaust Service Warning .

Note. The 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/express-g2500/2013-2013/remont/hoistjack/#general-information) .
  2. If equipped with a three-way catalytic converter pipe, remove the nuts retaining the catalytic converter pipe from the muffler flange.
  3. If equipped 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 three-way catalytic converter, install the retaining nuts and new gasket to the front of the muffler. Tighten the catalytic converter to muffler retaining nuts to 48 N.m (35 lb ft).
  4. If equipped with dual catalytic converter pipes, install the right catalytic converter in the muffler. 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. 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.

Scheme 7

Scheme 7: Exhaust Muffler Replacement (LC8, L96)
Scheme 7: Exhaust Muffler Replacement (LC8, L96)
CalloutComponent Name
WARNING: Refer to Exhaust Service Warning . WARNING: Refer to Eye Protection Warning . Preliminary Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Exhaust Muffler to Catalytic Converter Fasteners (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 45 N.m (33 lb ft)
2Exhaust Muffler Gasket NOTE: Replace with a NEW gasket.
3Exhaust Isolators NOTE: Clean and lubricate exhaust rods for ease of installation.
4Rear Exhaust Muffler
WARNING
Refer to Exhaust Service Warning .
WARNING
Refer to Eye Protection Warning .
CAUTION
Refer to Fastener Caution .
NOTE
Replace with a NEW gasket.
NOTE
Clean and lubricate exhaust rods for ease of installation.

Exhaust Muffler Replacement (LC8,L96)

  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/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 and tighten to 40 N.m (30 lb ft).
  3. Install the spare tire, if necessary.
  4. lower the vehicle.

Exhaust Heat Shield Replacement - Body Panel

Special Tools

J 34940 Rivet Gun

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
  2. Remove the rear propeller shaft from the vehicle.
  3. Use a suitable tail shaft plug to minimize fluid leakage after propeller shaft removal. For vehicles equipped with a one piece propeller shaft, refer to «One-Piece Propeller Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) . For vehicles equipped with a two piece propeller shaft, refer to «Two-Piece Propeller Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
  4. Using a 1/4 inch (6 mm) drill bit, remove the rivets from the heat shields, as necessary.
  5. Remove the exhaust tailpipe heat shield from the body panel.
  6. Remove three muffler heat shield rivets from the heat shield. The rear middle rivet is not easily accessible.
  7. If removal of heat shield is necessary, then body will need to be lifted of the frame for clearance. For access to other components, repositioning of the heat shield is recommended.
  8. Remove the front exhaust pipe heat shield from the body panel.
  1. Install the front exhaust pipe heat shield to the body panel.
  2. Install the rivets to the heat shield using the J 34940 rivet gun.
  3. Install the muffler heat shield to the body panel.
  4. Install the rivets to the heat shield using the J 34940 rivet gun.
  5. Install the exhaust tailpipe heat shield to the body panel.
  6. Install the rivets to the heat shield using the J 34940 rivet gun.
  7. Install the propeller shaft to the vehicle. For vehicles equipped with a one piece propeller shaft, refer to «One-Piece Propeller Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) . For vehicles equipped with a two piece propeller shaft, refer to «Two-Piece Propeller Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints) .
  8. Lower the vehicle.
  1. Raise and support the vehicle . Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
  2. Remove the exhaust system, if necessary.
  3. Remove the bolts retaining the heat shield to the frame.
  4. Remove the heat shield.
  5. It may be necessary to SLIGHTLY bend the heat shield for clearance to remove.
  1. Install the heat shield to the frame rail.
  2. Install the heat shield bolts and tighten to 12 N.m (106 lb in).
  3. Install the exhaust system, if necessary.
  4. Lower the vehicle.

Scheme 8

Scheme 8: Turbocharger Heat Shield Replacement
Scheme 8: Turbocharger Heat Shield Replacement
CalloutComponent Name
Preliminary Procedure Remove the engine cover. Refer to Engine Cover Replacement
1Turbocharger Heat Shield Bolt (Qty: 3) WARNING: Refer to Exhaust Service Warning . CAUTION: Refer to Fastener Caution Tighten 10 N.m (89 lb in)
2Turbocharger Heat Shield
WARNING
Refer to Exhaust Service Warning .
CAUTION
Refer to Fastener Caution

Turbocharger Heat Shield Replacement

Scheme 9

Scheme 9: Exhaust Pipe Heat Shield Replacement
Scheme 9: Exhaust Pipe Heat Shield Replacement
CalloutComponent Name
Preliminary Procedure Remove the engine cover. Refer to Engine Cover Replacement . Remove the indirect fuel injector from the turbocharger exhaust pipe and set aside. Refer to Indirect Fuel Injector Replacement .
1Turbocharger Exhaust Pipe Heat Shield Bolt (Qty: 3) WARNING: Refer to Exhaust Service Warning . CAUTION: Refer to Fastener Caution Tighten 10 N.m (89 lb in)
2Turbocharger Exhaust Pipe Heat Shield
WARNING
Refer to Exhaust Service Warning .
CAUTION
Refer to Fastener Caution

Exhaust Pipe Heat Shield Replacement

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

Illustration Tool Number/ Description EN-35314-A J-35314-A Exhaust Back Pressure Gauge

Scheme 10

Scheme 10: Special Tools
Scheme 10: Special Tools

See also:
• Strategy Based Diagnosis
• Diesel Particulate Filter (DPF) Service Regeneration
• Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
• Heated Oxygen Sensor Replacement - Bank 1 Sensor 1
• Tire and Wheel Removal and Installation (6-Lug Wheel)
• Wheelhouse Splash Shield Replacement
• Fastener Caution
• Lifting and Jacking the Vehicle
• Engine Cover Replacement
• Adhesives, Fluids, Lubricants, and Sealers
• Oil Level Indicator Tube Replacement
• Exhaust Service Warning
• Indirect Fuel Injector Replacement
• Protective Goggles and Glove Warning
• Exhaust System Inspection Caution
• Eye Protection Warning
• Battery Negative Cable Disconnection and Connection
• One-Piece Propeller Shaft Replacement
• Exhaust System Description
• Restricted Exhaust
• Exhaust Leakage
• Exhaust Noise
• Symptoms - Engine Exhaust
• Fastener Tightening Specifications
• Adhesives, Fluids, Lubricants, and Sealers