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Engine Exhaust System: Removal & Installation Chevrolet Silverado 1500

Exhaust 78 illustrations ~6596 words

Installation Procedure

  1. Install the heat shield (2), and bolts (3) to the exhaust manifold (1), if necessary. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts.
  3. Install the exhaust manifold, NEW gasket and bolts. Tighten: Tighten the bolts a first pass to 15 N.m (11 lb ft). Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the bolts a final pass to 25 N.m (18 lb ft). Tighten the bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
  4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.
  5. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-238175-S41717020612006072400000) .
  6. Raise the vehicle.
  7. Install the exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  8. Lower the vehicle.

Scheme 1

Scheme 1: Removal Procedure
Scheme 1: Removal Procedure

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3

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Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  2. Remove the exhaust pipe heat shield bolts.
  3. Reposition the heat shield to the side in order to access the exhaust pipe to exhaust manifold bolts.
  4. Lower the vehicle in order to work through the front wheelhouse opening.
  5. Remove the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-238206-S25170656262006072400000) .
  6. Remove the charged air cooler outlet duct. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Left)»(ref-238224-S26744735612006072400000) or «Charged Air Cooler Hoses/Pipes Replacement (Right)»(ref-238224-S09843896152006072400000) .
  7. Remove the exhaust pipe to exhaust manifold bolts (1, 2, and 3).
  8. Remove the exhaust manifold heat shield bolts.
  9. Remove the exhaust manifold heat shield.
  10. Remove the exhaust manifold bolts and nuts in the proper sequence.
  11. Remove the exhaust manifold.
  12. Remove and discard the exhaust manifold gasket.
  13. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(ref-238292-S26325565802006072400000) .
  1. Install the exhaust manifold with gasket.
  2. Install the exhaust manifold bolts/nuts.
  3. Use the sequence shown to properly tighten the exhaust manifold bolts. Tighten: Tighten the bolts/nut to 38 N.m (28 lb ft).
  4. Install the exhaust manifold heat shield.
  5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  6. Install the exhaust pipe gasket. Align the tab on the gasket to face outward.
  7. Install the exhaust pipe and the bolts (1, 2, and 3) to the exhaust manifold. Tighten: Tighten the bolts to 53 N.m (39 lb ft).
  8. Raise the vehicle.
  9. Install the exhaust pipe heat shield bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  10. Install the charged air cooler outlet duct. Refer to «Charged Air Cooler Hoses/Pipes Replacement (Left)»(ref-238224-S26744735612006072400000) or «Charged Air Cooler Hoses/Pipes Replacement (Right)»(ref-238224-S09843896152006072400000) .
  11. Install the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-238206-S25170656262006072400000) .
  12. Lower the vehicle.

Scheme 6

Scheme 6: Removal Procedure
Scheme 6: Removal Procedure

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8
  1. Remove the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-238206-S25170656262006072400000) . IMPORTANT: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged.
  2. Remove the spark plug wires from the spark plugs and ignition coils.
  3. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-238175-S41717020612006072400000) .
  4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  5. Remove the exhaust manifold heat shield bolts and nuts.
  6. Remove the left exhaust manifold heat shield.
  7. Lower the vehicle.
  8. Remove the exhaust manifold bolt and nuts.
  9. Remove the exhaust manifold.
  10. Remove and discard the exhaust manifold gasket.
  11. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(ref-238225-S28242722122006072400000) .
  1. Install a NEW exhaust manifold gasket.
  2. Install the exhaust manifold. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) .
  3. Install the exhaust manifold bolt and nuts. Tighten: Tighten the bolt to 35 N.m (26 lb ft). Tighten the nuts to 16 N.m (12 lb ft).
  4. Raise the vehicle.
  5. Install the exhaust manifold heat shield.
  6. Install the exhaust manifold heat shield bolts and nuts. Tighten: Tighten the bolts and nuts to 25 N.m (18 lb ft).
  7. Lower the vehicle.
  8. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-238175-S41717020612006072400000) .
  9. Install the spark plug wires to the spark plugs and ignition coils.
  10. Install the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-238206-S25170656262006072400000) .

Scheme 9

Scheme 9: Removal Procedure
Scheme 9: Removal Procedure

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Scheme 11

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Scheme 12

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Scheme 17

Scheme 17
Scheme 17
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  2. Remove the right exhaust manifold pipe nuts.
  3. Lower the vehicle.
  4. Loosen the air cleaner outlet duct clamp at the mass airflow/intake air temperature (MAF/IAT) sensor.
  5. Remove the positive crankcase ventilation (PCV) hose.
  6. Remove the air cleaner adapter nut.
  7. In order to remove the air cleaner outlet duct, pivot the duct upward until the hinge clip releases from the lip on the throttle body.
  8. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-238222-S28144847722006072400000) .
  9. Disconnect the spark plug wires from the spark plugs.
  10. Remove the spark plug wire retainer bolt.
  11. Reposition the wire retainer to the top of the engine.
  12. Remove the spark plugs.
  13. Remove the exhaust manifold and spark plug heat shield bolts.
  14. Remove the exhaust manifold and spark plug heat shields.
  15. Remove and discard the exhaust manifold gaskets.
  16. Remove the exhaust manifold heat shield, if required.
  17. Clean all gasket mating surfaces.

Scheme 18

Scheme 18
Scheme 18
  1. Install the exhaust manifold heat shield, if required. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) .
  2. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  3. Install NEW exhaust manifold gaskets to the exhaust manifold.
  4. Ensure that the exhaust manifold bolts, and plug wire shields are held in place by the tabs on the exhaust manifold gaskets.
  5. Install the exhaust manifold and plug wire shields.
  6. If reusing the old fasteners, apply threadlock GM P/N 12345493, (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts.
  7. Install the exhaust manifold bolts. Tighten: Tighten the bolts to 30 N.m (22 lb ft).
  8. Install the spark plugs.
  9. Position the spark plug wire retainer to the engine.
  10. Loosely install the spark plug wire retainer bolt.
  11. Connect the spark plug wires to the spark plugs.
  12. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-238222-S28144847722006072400000) .
  13. Tighten the spark plug wire retainer bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
  14. Align the hinge clip with the lip on the throttle body. In order to install the air cleaner outlet duct, pivot the air cleaner outlet duct downward until the mounting stud is through the hole.
  15. Install the air cleaner adapter nut.
  16. Install the PCV hose.
  17. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor.
  18. Raise the vehicle.
  19. Install the right exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  20. Lower the vehicle.

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  2. Remove the exhaust manifold pipe nuts.
  3. Lower the vehicle.
  4. Remove the oil level indicator tube. Refer to «OIL LEVEL INDICATOR AND TUBE REPLACEMENT»(ref-238223-S16348554702006072400000) .
  5. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-238175-S41717020612006072400000) .
  6. Remove the exhaust manifold bolts, manifold, and gasket.
  7. Discard the gasket.
  8. Remove the heat shield bolts (1), and shield (2) from the exhaust manifold (1), if necessary.
  9. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(ref-238290-S20924254352006072400000) .

Note. Refer to FASTENER NOTICE .

  1. Install the heat shield (2), and bolts (1) to the exhaust manifold (1), if necessary. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts.
  3. Install the exhaust manifold, NEW gasket and bolts. Tighten: Tighten the bolts a first pass to 15 N.m (11 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the bolts a final pass to 25 N.m (18 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
  4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.
  5. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-238175-S41717020612006072400000) .
  6. Install the oil level indicator tube. Refer to «OIL LEVEL INDICATOR AND TUBE REPLACEMENT»(ref-238223-S16348554702006072400000) .
  7. Raise the vehicle.
  8. Install the exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  9. Lower the vehicle.

Scheme 21

Scheme 21: Removal Procedure
Scheme 21: Removal Procedure

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24
  1. Raise the vehicle enough in order to work through the wheelhouse opening. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  2. Remove the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-238206-S25170656262006072400000) .
  3. Remove the exhaust manifold heat shield bolts.
  4. Remove the exhaust manifold heat shield.
  5. Remove the right exhaust pipe to the exhaust manifold bolts (3, 4, and 5).
  6. Remove the exhaust manifold bolts and nuts in the proper sequence.
  7. Remove the exhaust manifold.
  8. Remove the bolt for the oil level indicator tube bracket in order to remove the exhaust manifold gasket.
  9. Remove and discard the exhaust manifold gasket.
  10. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(ref-238292-S26325565802006072400000) .

Scheme 25

Scheme 25
Scheme 25
  1. Install the exhaust manifold gasket to the cylinder head. NOTE: Refer to «Fastener Notice»(ref-238188-S13145861262006072400000) .
  2. Install the bolt for the oil level indicator tube bracket. Tighten: Tighten the bolt to 21 N.m (15 lb ft).
  3. Install the exhaust manifold.
  4. Install the exhaust manifold bolts/nuts.
  5. Using the sequence shown, properly tighten the exhaust manifold bolts. Tighten: Tighten the bolt/nuts to 38 N.m (28 lb ft).
  6. Install the exhaust manifold heat shield.
  7. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  8. Install the exhaust pipe gasket. Align the tab on the gasket to face outward.
  9. Install the exhaust pipe bolts (3, 4, and 5). Tighten: Tighten the bolts to 53 N.m (39 lb ft).
  10. Install the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-238206-S25170656262006072400000) .
  11. Lower the vehicle.

Scheme 26

Scheme 26: Removal Procedure
Scheme 26: Removal Procedure

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28
  1. Remove the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-238206-S25170656262006072400000) .
  2. Remove the oil level indicator. Refer to «Oil Level Indicator and Tube Replacement»(ref-238225-S04807725192006072400000) . IMPORTANT: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug or the wire could be damaged.
  3. Remove the spark plug wires from the spark plugs and ignition coils.
  4. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-238175-S41717020612006072400000) .
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  6. Remove the exhaust manifold heat shield bolts and nuts.
  7. Remove the exhaust manifold heat shield.
  8. Lower the vehicle.
  9. Remove the exhaust manifold bolt and nuts.
  10. Remove the exhaust manifold.
  11. Remove and discard the exhaust manifold gasket.
  12. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(ref-238225-S28242722122006072400000) .
  1. Install the a NEW exhaust manifold gasket.
  2. Install the exhaust manifold. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) .
  3. Install the exhaust manifold bolt and nuts. Tighten: Tighten the bolt to 35 N.m (26 lb ft). Tighten the nuts to 16 N.m (12 lb ft).
  4. Raise and suitably support the vehicle with safety stands.
  5. Install the exhaust manifold heat shield.
  6. Install the exhaust manifold heat shield bolts and nuts. Tighten: Tighten the bolts/nuts to 25 N.m (18 lb ft).
  7. Lower the vehicle.
  8. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-238175-S41717020612006072400000) (8.1L).
  9. Install the spark plug wires to the spark plugs and ignition coils.
  10. Install the oil level indicator. Refer to «Oil Level Indicator and Tube Replacement»(ref-238225-S04807725192006072400000) .
  11. Install the wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-238206-S25170656262006072400000) .

Scheme 29

Scheme 29: Removal Procedure
Scheme 29: Removal Procedure

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Scheme 37
Scheme 37
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  2. Loosen the exhaust manifold pipe clamp.
  3. Slide the exhaust pipe clamp up onto the exhaust pipe.
  4. Remove the exhaust muffler nuts.
  5. Slide the exhaust manifold pipe hanger out from the insulator.
  6. Remove the exhaust manifold pipe.
  7. If equipped with an automatic transmission, remove the transmission fluid fill tube to bellhousing nuts.
  8. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.
  9. Lower the vehicle.
  10. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).
  11. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-238224-S15180051322006072400000) .
  12. Remove the turbocharger upper heat shield bolts.
  13. Remove the turbocharger upper heat shield.
  14. Remove the exhaust outlet heat shield bolts.
  15. Remove the exhaust outlet heat shield.
  16. Remove the exhaust outlet to right exhaust pipe bracket bolt.
  17. Loosen the exhaust outlet pipe clamp.
  18. Remove the exhaust outlet pipe.
  1. Install the exhaust outlet pipe.
  2. Tighten the exhaust outlet pipe clamp. Tighten: Tighten the clamp to 15 N.m (11 lb ft).
  3. Install the exhaust outlet to right exhaust pipe bracket bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
  4. Install the exhaust outlet heat shield.
  5. Install the exhaust outlet heat shield bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  6. Install the turbocharger upper heat shield.
  7. Install the turbocharger upper heat shield bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  8. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-238224-S15180051322006072400000) .
  9. Remove the hood hinge bolts (1) from the service position (2) and position the hood in the normal position. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  10. Raise the vehicle.
  11. If equipped with an automatic transmission, position the transmission fluid fill tube to the studs.
  12. Install the transmission fluid fill tube to bellhousing nuts. Tighten: Tighten the nuts to 18 N.m (13 lb ft).
  13. Install the exhaust manifold pipe.
  14. Slide the exhaust manifold pipe hanger into the insulator.
  15. Install the exhaust muffler nuts until snug.
  16. Slide the exhaust pipe clamp down onto the exhaust pipe.
  17. Tighten the exhaust manifold pipe clamp. Tighten: Tighten the clamp and nuts to 40 N.m (30 lb ft).
  18. Lower the vehicle.

Scheme 38

Scheme 38: Removal Procedure
Scheme 38: Removal Procedure

Scheme 39

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Scheme 40

Scheme 41

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Scheme 41

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Scheme 43

Scheme 43
Scheme 43
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  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. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler. Refer to «Muffler Replacement (6.0L, 6.6L, and 8.1L Engines)»(ref-238286-S01970875362006072400000) .
  8. If equipped with a 6.0L or 8.1L engine, perform the following: Remove the clip around the engine harness and the oxygen sensor pigtail. Disconnect the connector position assurance (CPA) retainer. Disconnect the oxygen sensor electrical connector. Remove the oxygen sensor.
  9. If equipped with a 6.0L or 8.1L engine, remove the exhaust manifold pipe nuts.
  10. Using the transmission jack, lower the transmission slightly.
  11. If equipped with the 6.6L engine, remove the exhaust muffler nuts.
  12. If equipped with a 6.6L engine, loosen the exhaust pipe clamp.
  13. Slide the exhaust pipe clamp up onto the exhaust pipe adapter.
  14. If equipped with a 6.0L or 8.1L engine, remove the exhaust manifold pipe.
  15. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket.
  16. Discard the exhaust manifold pipe seal.
  17. If equipped with a 6.0L engine, with RPO Y91, remove the exhaust manifold pipe.
  18. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket.
  19. Discard the exhaust manifold pipe seal.
  20. If equipped with a 6.6L engine, remove the exhaust manifold pipe.
  21. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket.
  1. If equipped with a 6.6L engine, install the exhaust manifold pipe.
  2. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation.
  3. Slide the exhaust manifold pipe hanger into the exhaust pipe hanger bracket.
  4. If equipped with a 6.0L engine, with RPO Y91, install a new exhaust manifold pipe seal to the exhaust manifold pipe.
  5. Install the exhaust manifold pipe.
  6. Apply lubricant to the exhaust pipe hanger bracket, in order to aid in installation.
  7. Slide the exhaust manifold pipe hanger into the exhaust pipe hanger bracket.
  8. If equipped with a 6.0L or 8.1L engine, install a new exhaust manifold pipe seal to the exhaust manifold pipe.
  9. Install the exhaust manifold pipe.
  10. Apply lubricant to the exhaust pipe hanger bracket, in order to aid in installation.
  11. Slide the exhaust manifold pipe hanger into the exhaust pipe hanger bracket.
  12. If equipped with the 6.6L engine, install the exhaust muffler nuts until snug.
  13. If equipped with a 6.6L engine, slide the exhaust pipe clamp down and around the pipe connection.
  14. Tighten the exhaust pipe clamp and muffler nuts. Tighten: Tighten the clamp to 40 N.m (30 lb ft). Tighten the nuts to 40 N.m (30 lb ft).
  15. If equipped with a 6.0L or 8.1L engine, install the exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (39 lb ft).
  16. Using the transmission jack, raise the transmission.
  17. If equipped with a 6.0L or 8.1L engine, and the exhaust manifold pipe was replaced perform the following: Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensor. Install the old oxygen sensor. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  18. If equipped with a 6.0L or 8.1L engine, and the exhaust manifold pipe was not replaced perform the following: Connect the oxygen sensor electrical connector. Connect the CPA retainer. Install the clip around the engine harness and the oxygen sensor pigtail.
  19. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler. Refer to «Muffler Replacement (6.0L, 6.6L, and 8.1L Engines)»(ref-238286-S01970875362006072400000) .
  20. Install the transmission support crossmember.
  21. Install the transmission support crossmember bolts. Tighten: Tighten the bolts to 95 N.m (70 lb ft).
  22. Lower the transmission onto the transmission support.
  23. Install the transmission mount to transmission support nuts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  24. Remove the support from the transmission.
  25. Lower the vehicle.

Scheme 44

Scheme 44: Removal Procedure
Scheme 44: Removal Procedure

Scheme 45

Scheme 45
Scheme 45
  1. Remove the right wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-238206-S25170656262006072400000) .
  2. Remove the exhaust heat shield nuts (2) and heat shield (3) from the dash panel.
  3. Remove the left exhaust pipe heat shield bolts.
  4. Remove the heat shield.
  5. Remove the exhaust pipe bolts in the proper sequence.
  6. Remove the exhaust pipe and gaskets.
  7. Discard the gaskets.
  1. Position the exhaust pipe with a NEW gasket to the turbocharger. Align the tab on the gasket at the turbocharger to face inward.
  2. Loosely install the bolts.
  3. Position the exhaust pipe with a NEW gasket to the exhaust manifold. Align the tab on the gasket to face outward.
  4. Loosely install the bolts.
  5. Tighten the exhaust pipe bolts in the sequence shown. Tighten: Tighten the bolts to 53 N.m (39 lb ft).
  6. Install the exhaust pipe heat shield bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  7. Install the left side exhaust heat shield (3) at the dash panel.
  8. Install the heat shield nuts (2). Tighten: Tighten the nuts to 9 N.m (80 lb in).
  9. Install the right wheelhouse panel. Refer to «Wheelhouse Panel Replacement»(ref-238206-S25170656262006072400000) .

Scheme 46

Scheme 46
Scheme 46
  1. Remove the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L (LLY) Engine)»(ref-238286-S15731561002006072400000) .
  2. Remove the exhaust pipe bolts in the proper sequence.
  3. Remove the exhaust pipe, bracket and gaskets.
  4. Discard the gaskets.
  1. Position the exhaust pipe with a NEW gasket to the turbocharger. Align the tab on the gasket at the turbocharger to face inward.
  2. Loosely install the bolts.
  3. Position the exhaust pipe with a NEW gasket to the exhaust manifold. Align the tab on the gasket to face outward.
  4. Loosely install the bolts.
  5. Tighten the exhaust pipe bolts in the proper sequence. Tighten: Tighten the bolts to 53 N.m (39 lb ft).
  6. Remove the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L (LLY) Engine)»(ref-238286-S15731561002006072400000) .

Scheme 47

Scheme 47: Removal Procedure
Scheme 47: Removal Procedure

Scheme 48

Scheme 48
Scheme 48

Scheme 49

Scheme 49
Scheme 49

Scheme 50

Scheme 50
Scheme 50
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  2. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: Remove the clip from around the engine harness and the oxygen sensor pigtail. Disconnect the connector position assurance (CPA) retainer. Disconnect the forward oxygen sensor electrical connector.
  3. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: Unclip the oxygen sensor electrical connector from the hose clip. Disconnect the CPA retainer. Disconnect the oxygen sensor electrical connector (1).
  4. If equipped with a 6.0L or 8.1L engine, perform the following: Disconnect the CPA retainer. Disconnect the oxygen sensor electrical connector (1).
  5. Support the catalytic converter or exhaust manifold pipe with adjustable jackstands.
  6. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the left exhaust manifold pipe nuts.
  7. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the right exhaust manifold pipe nuts.
  8. If equipped with a 6.0L or 8.1L engine, remove the right exhaust manifold pipe nuts.
  9. If equipped with a 6.0L or 8.1L engine, perform the following: Remove the left exhaust manifold pipe nuts. Remove the exhaust hanger mounting bracket bolts.
  10. Lower the catalytic converter or exhaust manifold pipe using the adjustable jackstands.
  11. Remove the exhaust manifold pipe seal(s).
  1. Install the exhaust manifold pipe seal(s).
  2. Raise the catalytic converter or exhaust manifold pipe using the adjustable jackstands.
  3. If equipped with a 6.0L or 8.1L engine, perform the following: Install the exhaust hanger mounting bracket bolts. Install the left exhaust manifold pipe nuts. Tighten: Tighten the bolts to 12 N.m (106 lb in). Tighten the nuts to 50 N.m (39 lb ft).
  4. If equipped with a 6.0L or 8.1L engine, install the right exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (39 lb ft).
  5. If equipped with a 4.3L, 4.8L, or 5.3L engine, install the right exhaust manifold pipe nuts.
  6. If equipped with a 4.3L, 4.8L, or 5.3L engine, install the left exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (39 lb ft).
  7. If equipped with a 6.0L or 8.1L engine, perform the following: Connect the oxygen sensor electrical connector (1). Connect the CPA retainer.
  8. Remove the adjustable jackstands from catalytic converter or exhaust manifold pipe.
  9. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: Connect the oxygen sensor electrical connector (1). Connect the CPA retainer. Clip the oxygen sensor electrical connector to the hose clip.
  10. If equipped with a 4.3L, 4.8L, or 5.3L engine, perform the following: Connect the forward oxygen sensor electrical connector. Connect the CPA retainer. Install the clip around the engine harness and the oxygen sensor pigtail.
  11. Lower the vehicle.

Scheme 51

Scheme 51: Removal Procedure
Scheme 51: Removal Procedure

Scheme 52

Scheme 52
Scheme 52

Scheme 53

Scheme 53
Scheme 53
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  2. If equipped, unclip the oxygen sensor connection from the floor reinforcement.
  3. Disconnect the oxygen sensor electrical connector.
  4. Remove the oxygen sensor clips from the frame.
  5. Disconnect the connector position assurance (CPA) retainers.
  6. Disconnect the oxygen sensor electrical connectors.
  7. Unclip the oxygen sensors electrical connectors from the following: Hose clip Transmission crossmember
  8. Disconnect the CPA retainers.
  9. Disconnect the oxygen sensor electrical connectors (1, 2).
  10. Remove the left exhaust manifold pipe nuts.
  11. Remove the right exhaust manifold pipe nuts.
  12. Remove the exhaust muffler nuts.
  13. Remove the catalytic converter.
  14. If necessary, remove the oxygen sensors.

Note. Refer to FASTENER NOTICE .

  1. If necessary, install the oxygen sensors. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. Install the oxygen sensors. Tighten: Tighten the sensors to 42 N.m (31 lb ft).
  2. Install the catalytic convertor.
  3. Install NEW exhaust manifold pipe seals to the exhaust manifolds.
  4. Install the right exhaust manifold pipe nuts until snug.
  5. Install the left exhaust manifold pipe nuts until snug.
  6. Tighten the exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (39 lb ft).
  7. Install the exhaust muffler nuts. Tighten: Tighten the nuts to 40 N.m (30 lb ft).
  8. Connect the oxygen sensor electrical connectors (1, 2).
  9. Connect the CPA retainers.
  10. Clip the oxygen sensors electrical connectors to the following: Hose clip Transmission crossmember
  11. Connect the oxygen sensor electrical connectors.
  12. Connect the CPA retainers.
  13. Install the clip around the engine harness and the oxygen sensor pigtail.
  14. Connect the oxygen sensor electrical connector.
  15. If equipped, clip the oxygen sensor connection to the floor reinforcement.
  16. Lower the vehicle.

Scheme 54

Scheme 54
Scheme 54

Scheme 55

Scheme 55
Scheme 55
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  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 muffler. Refer to «Muffler Replacement (6.0L, 6.6L, and 8.1L Engines)»(ref-238286-S01970875362006072400000) .
  8. Disconnect the connector position assurance (CPA) retainers.
  9. Disconnect the oxygen sensor electrical connectors (1, 2).
  10. Loosen the right exhaust manifold pipe nuts.
  11. Remove the left exhaust manifold pipe nuts.
  12. Using the transmission jack, lower the transmission slightly.
  13. Remove the catalytic converter.
  14. Slide the catalytic converter hanger out of the exhaust pipe hanger bracket.
  15. If equipped with a 6.0L engine, with regular production option (RPO) Y91, remove the catalytic converter.
  16. Slide the catalytic converter hanger out of the exhaust pipe hanger bracket.
  17. Remove the oxygen sensors if the catalytic converter is to be replaced.

Note. Refer to FASTENER NOTICE .

  1. If the catalytic converter was replaced, perform the following: Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. Install the oxygen sensors. Tighten: Tighten the sensors to 42 N.m (31 lb ft).
  2. If equipped with a 6.0L engine, with RPO Y91, install a NEW exhaust seal to the exhaust manifold.
  3. Install the catalytic converter. Slide the catalytic converter hanger into the exhaust pipe hanger bracket.
  4. Install a NEW exhaust seal to the exhaust manifold.
  5. Install the catalytic converter. Slide the catalytic converter hanger into the exhaust pipe hanger bracket.
  6. Install the left exhaust manifold pipe nuts.
  7. Tighten the right exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (39 lb ft).
  8. Using the transmission jack, raise the transmission slightly.
  9. Connect the oxygen sensor electrical connectors (1, 2).
  10. Connect the CPA retainers.
  11. Install the muffler. Refer to «Muffler Replacement (6.0L, 6.6L, and 8.1L Engines)»(ref-238286-S01970875362006072400000) .
  12. Install the transmission support crossmember.
  13. Install the transmission support crossmember bolts. Tighten: Tighten the bolts to 95 N.m (70 lb ft).
  14. Lower the transmission onto the transmission support.
  15. Install the transmission mount to transmission support nuts. Tighten: Tighten the nuts to 40 N.m (30 lb ft).
  16. Remove the support from the transmission.
  17. Lower the vehicle.

Scheme 56

Scheme 56
Scheme 56
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  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. If equipped with the 6.6L engine, remove the exhaust muffler nuts.
  8. If equipped with a 6.6L engine, loosen the exhaust pipe clamp.
  9. Slide the exhaust pipe clamp up onto the exhaust pipe adapter.
  10. If equipped with a 6.6L engine, remove the catalytic converter.
  11. Slide the catalytic converter hanger out of the exhaust pipe hanger bracket.
  1. If equipped with a 6.6L engine, 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. If equipped with the 6.6L engine, install the exhaust muffler nuts until snug.
  5. If equipped with a 6.6L engine, slide the exhaust pipe clamp down and around the pipe connection.
  6. Tighten the exhaust pipe clamp and muffler 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.

Scheme 57

Scheme 57: Removal Procedure
Scheme 57: Removal Procedure
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  2. Remove the exhaust muffler hanger nuts.
  3. Remove the hanger from the hanger insulator.
  1. Install the hanger into the hanger insulator. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) .
  2. Install the exhaust muffler hanger nuts. Tighten: Tighten the nuts to 50 N.m (39 lb ft).
  3. Lower the vehicle.

Scheme 58

Scheme 58: Removal Procedure
Scheme 58: Removal Procedure

Scheme 59

Scheme 59
Scheme 59

Scheme 60

Scheme 60
Scheme 60

Scheme 61

Scheme 61
Scheme 61

Scheme 62

Scheme 62
Scheme 62

Scheme 63

Scheme 63
Scheme 63

Scheme 64

Scheme 64
Scheme 64
  1. Remove the exhaust manifold pipe. Refer to «Exhaust Manifold Pipe Replacement (6.0L, 6.6L, and 8.1L Engines)»(ref-238286-S10152765842006072400000) .
  2. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (6.0L and 8.1L Engines)»(ref-238286-S22015708302006072400000) or «Catalytic Converter Replacement (6.6L Engine)»(ref-238286-S22388962152006072400000) .
  3. If equipped with a 4L60-E automatic transmission, remove the exhaust pipe hanger bracket bolts.
  4. If equipped with a 6.0L engine and a 4L80-E automatic transmission, remove the exhaust pipe hanger bracket bolts.
  5. If equipped with a 6.0L, or 8.1L engine and a 4L80-E automatic transmission, remove the exhaust pipe hanger bracket bolts.
  6. If equipped with a 6.0L engine and a 5-speed manual transmission, remove the transmission bolts.
  7. If equipped with a 6.0L engine and a 5-speed manual transmission, remove the exhaust pipe hanger bracket bolts.
  8. If equipped with a 6.6L or 8.1L engine and a Allison transmission, remove the exhaust pipe hanger bracket bolts.
  9. If equipped with a 6.6L or 8.1L engine and a 6-speed manual transmission, remove the exhaust pipe hanger bracket bolts.
  10. Remove the exhaust manifold pipe bracket.
  1. Install the exhaust manifold pipe bracket. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) .
  2. If equipped with a 6.6L or 8.1L engine and a 6-speed manual transmission, install the exhaust pipe hanger bracket bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  3. If equipped with a 6.6L or 8.1L engine and a Allison transmission, install the exhaust pipe hanger bracket bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  4. If equipped with a 6.0L engine and a 5-speed manual transmission, install the exhaust pipe hanger bracket bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  5. If equipped with a 6.0L engine and a 5-speed manual transmission, install the transmission bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
  6. If equipped with a 6.0L or 8.1L engine and a 4L80-E automatic transmission, install the exhaust pipe hanger bracket bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  7. If equipped with a 6.0L engine and a 4L80-E automatic transmission, install the exhaust pipe hanger bracket bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
  8. If equipped with a 4L60-E automatic transmission, install the exhaust pipe hanger bracket bolts. Tighten: Tighten the bolts to 17 N.m (13 lb ft).
  9. Install the catalytic converter. Refer to «Catalytic Converter Replacement (6.0L and 8.1L Engines)»(ref-238286-S22015708302006072400000) or «Catalytic Converter Replacement (6.6L Engine)»(ref-238286-S22388962152006072400000) .
  10. Install the exhaust manifold pipe. Refer to «Exhaust Manifold Pipe Replacement (6.0L, 6.6L, and 8.1L Engines)»(ref-238286-S10152765842006072400000) .

Scheme 65

Scheme 65
Scheme 65
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  2. Remove the exhaust muffler nuts.
  3. Apply lubricant to the exhaust insulators in order to aid in removal.
  4. Remove the muffler brackets from the insulators.
  5. Remove the exhaust muffler.
  1. Apply lubricant to the exhaust insulators in order to aid in installation.
  2. Install the muffler to the insulators.
  3. Install the exhaust muffler nuts. Tighten: Tighten the nuts to 40 N.m (30 lb ft).

Scheme 66

Scheme 66: Removal Procedure
Scheme 66: Removal Procedure

Scheme 67

Scheme 67
Scheme 67

Scheme 68

Scheme 68
Scheme 68

Scheme 69

Scheme 69
Scheme 69

Scheme 70

Scheme 70
Scheme 70

Scheme 71

Scheme 71
Scheme 71

Scheme 72

Scheme 72
Scheme 72
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  2. Remove the spare tire, if necessary.
  3. Install adjustable jack stands under the rear axle, if necessary.
  4. If equipped with a 8.6 or 9.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary.
  5. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.
  6. If equipped with a 10.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary.
  7. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary.
  8. Remove the rear shock absorbers lower bolts and nuts, if necessary.
  9. Lower the rear axle using the adjustable jack stands, if necessary.
  10. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler nuts.
  11. Loosen the exhaust pipe clamp.
  12. With the aid of an assistant, support the exhaust muffler.
  13. If equipped with a 6.6L engine, remove the exhaust muffler nuts.
  14. With the aid of an assistant, support the exhaust muffler.
  15. If equipped with a 6.0L or 8.1L engine, remove the insulators from the frame hangers.
  16. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the catalytic converter.
  17. Remove the insulators from the muffler hangers.
  18. Remove the exhaust manifold pipe gasket, if necessary.
  19. If equipped with a 6.6L engine, remove the insulators from the frame hangers.
  20. With the aid of an assistant, slide the muffler rearward in order to remove the muffler from the exhaust muffler pipe.
  21. Remove the exhaust muffler gasket, if necessary.
  22. Remove the insulators from the muffler hangers.
  23. If equipped with a 6.0L or 8.1L engine, remove the oxygen sensor if the muffler is being replaced.
  24. If the muffler is NOT being replaced as an assembly, the band clamp MUST be replaced. Perform the following: Mark the position of the band clamp on the intermediate exhaust pipe. Remove the band clamp from the exhaust pipe by grinding the weld. Install a NEW band clamp onto the exhaust pipe.
  1. If equipped with a 6.0L or 8.1L engine, and the muffler was replaced re-install the old oxygen sensor.
  2. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensor. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) .
  3. Install the oxygen sensor. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  4. If equipped with a 6.6L engine, install the insulators to the muffler hangers.
  5. Install a new exhaust muffler gasket.
  6. With the aid of an assistant, slide the muffler forward in order to install the muffler to the exhaust muffler pipe.
  7. Install the insulators to the frame hangers.
  8. If equipped with a 6.0L or 8.1L engine, install the insulators to the muffler hangers.
  9. Install a new exhaust manifold pipe gasket.
  10. With the aid of an assistant, slide the muffler forward in order to install the muffler to the catalytic converter.
  11. Install the insulators to the frame hangers.
  12. If equipped with a 6.6L engine, install the exhaust muffler nuts. Tighten: Tighten the nuts to 40 N.m (30 lb ft).
  13. If equipped with a 6.0L or 8.1L engine, position the NEW band clamp on the intermediate exhaust pipe, using the alignment mark created previously. The band clamp bolt must NOT be positioned below the exhaust pipe.
  14. Install the exhaust muffler nuts.
  15. 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).
  16. Raise the rear axle using the adjustable jack stands, if necessary.
  17. Install the rear shock absorbers lower bolts and nuts, if necessary. Tighten: Tighten the bolts to 95 N.m (70 lb ft).
  18. If equipped with a 10.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  19. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  20. If equipped with a 8.6 or 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  21. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  22. Remove the adjustable jack stands from under the rear axle, if necessary.
  23. Install the spare tire, if necessary.
  24. Lower the vehicle.

Scheme 73

Scheme 73: Removal Procedure
Scheme 73: Removal Procedure

Scheme 74

Scheme 74
Scheme 74

Scheme 75

Scheme 75
Scheme 75

Scheme 76

Scheme 76
Scheme 76
  1. Remove the exhaust manifold pipe, if necessary. Refer to «Exhaust Manifold Pipe Replacement (6.0L, 6.6L, and 8.1L Engines)»(ref-238286-S10152765842006072400000) .
  2. Remove the catalytic converter, if necessary. Refer to «Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines)»(ref-238286-S42776935852006072400000) , «Catalytic Converter Replacement (6.0L and 8.1L Engines)»(ref-238286-S22015708302006072400000) or «Catalytic Converter Replacement (6.6L Engine)»(ref-238286-S22388962152006072400000) .
  3. Remove the exhaust front heat shield nuts.
  4. Remove the exhaust front heat shield from the studs.
  5. If vehicle is a regular cab pick-up truck, remove the exhaust heat shield nuts.
  6. Remove the exhaust front heat shield (1) and/or the exhaust heat shield (2) from the studs.
  7. If vehicle is a extended cab pick-up truck, remove the exhaust heat shield nuts.
  8. Remove the exhaust heat shield (1, 2) from the studs.
  9. If vehicle is a crew cab pick-up truck, remove the exhaust heat shield nuts.
  10. Remove the exhaust heat shields from the studs.
  1. If vehicle is a crew cab pick-up truck, install the exhaust heat shields to the studs.
  2. Install the exhaust heat shield nuts. Tighten: Tighten the exhaust heat shield nuts to 9 N.m (80 lb in).
  3. If vehicle is a extended cab pick-up truck, install the exhaust heat shield (1, 2) to the studs.
  4. Install the exhaust heat shield nuts. Tighten: Tighten the exhaust heat shield nuts to 9 N.m (80 lb in).
  5. If vehicle is a regular cab pick-up truck, install the exhaust front heat shield (1) and/or the exhaust heat shield (2) to the studs.
  6. Install the exhaust heat shield nuts. Tighten: Tighten the exhaust heat shield nuts to 9 N.m (80 lb in).
  7. Install the exhaust front heat shield to the studs.
  8. Install the exhaust front heat shield nuts. Tighten: Tighten the exhaust heat shield nuts to 9 N.m (80 lb in).
  9. Install the catalytic converter, if necessary. Refer to «Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines)»(ref-238286-S42776935852006072400000) , «Catalytic Converter Replacement (6.0L and 8.1L Engines)»(ref-238286-S22015708302006072400000) or «Catalytic Converter Replacement (6.6L Engine)»(ref-238286-S22388962152006072400000) .
  10. Install the exhaust manifold pipe, if necessary. Refer to «Exhaust Manifold Pipe Replacement (6.0L, 6.6L, and 8.1L Engines)»(ref-238286-S10152765842006072400000) .

Scheme 77

Scheme 77: Removal Procedure
Scheme 77: Removal Procedure

Scheme 78

Scheme 78
Scheme 78
  1. Remove the exhaust muffler. Refer to «Muffler Replacement (4.3L, 4.8L, and 5.3L Engines)»(ref-238286-S01873737522006072400000) or «Muffler Replacement (6.0L, 6.6L, and 8.1L Engines)»(ref-238286-S01970875362006072400000) .
  2. Remove the spare tire hoist. Refer to «Tire Hoist and Shaft Replacement»(ref-238261-S42526473352006072400000) .
  3. If equipped with a 6 1/2 ft box, remove the exhaust heat shield bolts.
  4. Remove the exhaust heat shield.
  5. If equipped with a 8 ft box, remove the exhaust heat shield bolts.
  6. Remove the exhaust heat shield.
  1. if equipped with a 8 ft box, install the exhaust heat shield. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) .
  2. Install the exhaust heat shield bolts. Tighten: Tighten the exhaust heat shield bolts to 9 N.m (80 lb in).
  3. if equipped with a 6 1/2 ft box, install the exhaust heat shield.
  4. Install the exhaust heat shield bolts. Tighten: Tighten the exhaust heat shield bolts to 9 N.m (80 lb in).
  5. Install the spare tire hoist. Refer to «Tire Hoist and Shaft Replacement»(ref-238261-S42526473352006072400000) .
  6. Install the exhaust muffler. Refer to «Muffler Replacement (4.3L, 4.8L, and 5.3L Engines)»(ref-238286-S01873737522006072400000) or «Muffler Replacement (6.0L, 6.6L, and 8.1L Engines)»(ref-238286-S01970875362006072400000) .

Removal Procedure

  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-238215-S26215505352006072400000) .
  2. Remove the exhaust heat shield nuts.
  3. Remove the exhaust heat shield (1, 3) from the dash panel studs.
  4. If removing the heat shield (3), remove the shield out through the passenger side wheelwell.
  1. If installing the heat shield (3), install the shield through the passenger side wheelwell.
  2. Install the exhaust heat shield (1, 3) to the dash panel studs. NOTE: Refer to «FASTENER NOTICE»(ref-246412-S41332073762006122100000) .
  3. Install the exhaust heat shield nuts. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  4. Lower the vehicle.

More articles — Engine Exhaust System