Engine Exhaust System: Removal & Installation Chevrolet Silverado 2500

Installation Procedure

1. Install the exhaust manifold heat shield and bolts, if required. Tighten the exhaust manifold heat shield bolts to 9 N.m (80 lb in). Important: To assist in installing the exhaust manifold and gasket to the engine, tabs on a NEW exhaust manifold gasket will hold the gasket and bolts in place.
2. Install NEW exhaust manifold gaskets to the exhaust manifold.
3. Ensure that the exhaust manifold bolts/stud, and plug wire shields are held in place by the tabs on the exhaust manifold gaskets.
4. Install the exhaust manifold and plug wire shields.
5. If reusing the old fasteners, apply threadlock GM P/N United States 12345493, GM P/N Canada 10953488, or equivalent to the threads of the exhaust manifold bolts/stud.
6. Tighten the exhaust manifold bolts/stud. Tighten the exhaust manifold bolts/stud to 30 N.m (22 lb ft).
7. Connect the ECT sensor electrical connector.
8. Install the EGR valve inlet pipe to the intake and exhaust manifolds. Tighten the EGR valve inlet pipe fitting to the intake manifold to 25 N.m (18 lb ft). Tighten the EGR valve inlet pipe fitting to the exhaust manifold to 30 N.m (22 lb ft).
9. Install the spark plugs. Tighten the spark plugs to 15 N.m (11 lb ft).
10. Position the wire harness to the engine.
11. Install the spark plug wire retainer bolts. Tighten the spark plug wire retainer bolts to 12 N.m (106 lb in).
12. Connect the spark plug wires to the spark plugs.
13. Install the spark plug wire clip to the EGR valve inlet pipe tab.
14. Raise the vehicle.
15. Install the exhaust manifold pipe nuts. Tighten the exhaust manifold pipe nuts to 50 N.m (37 lb ft).
16. Lower the vehicle.

Scheme 11

1. Raise and suitably support the vehicle.
2. Remove the exhaust manifold pipe nuts.
3. Lower the vehicle.
4. Remove the spark plugs.
5. Remove the exhaust manifold bolts, manifold, and gasket.
6. Discard the gasket.
7. Remove the heat shield bolts (3), and shield (2) from the exhaust manifold (1), if necessary.
8. Clean and inspect the exhaust manifold.

1. Install the heat shield (2), and bolts (3) to the exhaust manifold (1), if necessary. Tighten the exhaust manifold heat shield bolts to 9 N.m (68 lb in). Important: Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Important: Do not apply sealant to the first three threads of the bolt.
2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N United States 12345493 GM P/N Canada 10953488, or equivalent to the threads of the exhaust manifold bolts.
3. Install the exhaust manifold, NEW gasket and bolts. 3.1. Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. 3.2. Tighten the exhaust manifold bolts a first pass to 25 N.m (18 lb ft). Tighten the exhaust manifold 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.
6. Raise the vehicle.
7. Install the exhaust manifold pipe nuts. Tighten the exhaust manifold pipe nuts to 50 N.m (37 lb ft).
8. Lower the vehicle.

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Scheme 15

1. Raise and suitably support the vehicle.
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. Remove the exhaust pipe to exhaust manifold bolts (2).
5. Lower the vehicle in order to work through the front wheelhouse opening.
6. Remove the wheelhouse panel.
7. Remove the front tire and wheel.
8. Remove the charged air cooler outlet duct.
9. Remove the exhaust manifold heat shield bolts.
10. Remove the exhaust manifold heat shield.
11. Remove the exhaust manifold bolts/nuts.
12. Remove the exhaust manifold. 12.1. Remove the manifold from the rear stud. 12.2. Remove the manifold from the front stud. 12.3. Slide the manifold out the bottom, past the oil filter.
13. Remove and discard the exhaust manifold gasket.
14. Clean and inspect the exhaust manifold.

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. 3.1. Tighten the exhaust manifold bolts/nut a first pass to 34 N.m (25 lb ft). 3.2. Tighten the exhaust manifold bolts/nuts a final pass to 34 N.m (25 lb ft).
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten the exhaust manifold heat shield 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 (2) to the exhaust manifold. Tighten the exhaust pipe to exhaust manifold bolts to 53 N.m (39 lb ft).
8. Raise the vehicle.
9. Install the exhaust pipe heat shield bolts. Tighten the exhaust pipe heat shield bolts to 8 N.m (71 lb in).
10. Install the charged air cooler outlet duct.
11. Install the wheelhouse panel.
12. Install the front tire and wheel.
13. Lower the vehicle.

Removal Procedure

1. Remove the wheelhouse panel. 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.
4. Raise and suitably support the vehicle with safety stands.
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.

1. Install a NEW exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolt and nuts. Tighten the exhaust manifold bolt to 35 N.m (26 lb ft). Tighten the exhaust manifold 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 the heat shield bolts and nuts to 25 N.m (18 lb ft).
7. Lower the vehicle.
8. Install the spark plugs. Important: Fully install the spark plug wire by pushing on the exposed end of the spark plug boot. Do not push the spark plug wire on to the spark plug by using the metal heat shield.
9. Install the spark plug wires to the spark plugs and ignition coils.
10. Install the wheelhouse panel.

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1. Raise and suitably support the vehicle.
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.
9. Disconnect the spark plug wires from the spark plugs.
10. Remove the spark plug wire retainer bolt.
11. Reposition the wire retainer to the top of the engine.
12. Remove the spark plugs.
13. Remove the exhaust manifold and spark plug heat shield bolts.
14. Remove the exhaust manifold and spark plug heat shields.
15. Remove and discard the exhaust manifold gaskets.
16. Remove the exhaust manifold heat shield, if required.
17. Clean all gasket mating surfaces.

1. Install the exhaust manifold heat shield to, if required.
2. Install the exhaust manifold heat shield bolts. Tighten the exhaust manifold heat shield bolts to 9 N.m (80 lb in). Important: To assist in installing the exhaust manifold and gasket to the engine, tabs on a NEW exhaust manifold gasket will hold the gasket and bolts in place.
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 United States 12345493, GM P/N Canada 10953488, or equivalent to the threads of the exhaust manifold bolts.
7. Tighten the exhaust manifold bolts. Tighten the exhaust manifold 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. Tighten the spark plug wire retainer bolt to 12 N.m (106 lb in).
13. 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.
14. Install the air cleaner adapter nut.
15. Install the PCV hose.
16. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor.
17. Raise the vehicle.
18. Install the right exhaust manifold pipe nuts. Tighten the exhaust manifold pipe nuts to 50 N.m (37 lb ft).
19. Lower the vehicle.

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

1. Raise and suitably support the vehicle.
2. Remove the exhaust manifold pipe nuts.
3. Lower the vehicle.
4. Remove the oil level indicator tube. Refer to «OIL LEVEL INDICATOR & TUBE REMOVAL»(ref-176271-S01100977722005050300000) in ENGINE MECHANICAL - 4.8L, 5.3L & 6.0L article.
5. Remove the spark plugs.
6. Remove the bolts (1, 2, 3) attaching the exhaust gas recirculation (EGR) valve pipe to the following, if equipped: Intake manifold Cylinder head Exhaust manifold
7. Remove the EGR valve pipe and gaskets, if equipped. With mild force, pull the EGR valve pipe from the intake manifold.
8. Remove the O-ring seal from the EGR valve pipe, if equipped.
9. Discard the gasket and the O-ring seal, if equipped.
10. Remove the exhaust manifold bolts, manifold, and gasket.
11. Discard the gasket.
12. Remove the heat shield bolts (1), and shield (2) from the exhaust manifold (1), if necessary.
13. Clean and inspect the exhaust manifold.

1. Install the heat shield (2), and bolts (1) to the exhaust manifold (1), if necessary. Tighten the exhaust manifold heat shield bolts to 9 N.m (80 lb in). Important: Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance. The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Important: Do not apply sealant to the first three threads of the bolt.
2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N United States 12345493, GM P/N Canada 10953488, or equivalent to the threads of the exhaust manifold bolts.
3. Install the exhaust manifold, NEW gasket and bolts. 3.1. Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 3.2. Tighten the exhaust manifold bolts a final pass to 25 N.m (18 lb ft). Tighten the exhaust manifold 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. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe, if equipped.
6. Install the EGR pipe, if equipped.
7. Install the EGR valve pipe bolts until snug, if equipped. 7.1. Tighten the EGR valve pipe to intake manifold bolt (1) to 10 N.m (89 lb in). 7.2. Tighten the EGR valve pipe to cylinder head bolts (2) to 50 N.m (37 lb ft). 7.3. Tighten the EGR valve pipe to exhaust manifold bolts (3) to 30 N.m (22 lb ft).
8. Install the spark plugs.
9. Install the oil level indicator tube. Refer to «OIL LEVEL INDICATOR & TUBE INSTALLATION»(ref-176271-S09193280292005050300000) in ENGINE MECHANICAL - 4.8L, 5.3L & 6.0L article.
10. Raise the vehicle.
11. Install the exhaust manifold pipe nuts. Tighten the exhaust manifold pipe nuts to 50 N.m (37 lb ft).
12. Lower the vehicle.

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Scheme 22

1. Raise the vehicle enough in order to work through the wheelhouse opening.
2. Remove the wheelhouse panel.
3. Remove the front tire and wheel, if necessary.
4. Remove the exhaust manifold heat shield bolts.
5. Remove the exhaust manifold heat shield.
6. Remove the right exhaust pipe to the exhaust manifold bolts (1).
7. Remove the bolts/nuts from the right exhaust manifold.
8. Remove the exhaust manifold.
9. Remove the bolt for the oil level indicator tube bracket in order to remove the exhaust manifold gasket.
10. Remove and discard the exhaust manifold gasket.
11. Clean and inspect the exhaust manifold.

1. Install the exhaust manifold gasket to the cylinder head.
2. Install the bolt for the oil level indicator tube bracket. Tighten the oil level indicator tube bracket bolt to 21 N.m (15 lb ft).
3. Install the exhaust manifold.
4. Install the exhaust manifold bolts/nuts.
5. Use the sequence shown, properly tighten the exhaust manifold bolts. 5.1. Tighten the exhaust manifold bolt/nuts a first pass to 34 N.m (25 lb ft). 5.2. Tighten the exhaust manifold bolts/nuts a final pass to 34 N.m (25 lb ft).
6. Install the exhaust manifold heat shield.
7. Install the exhaust manifold heat shield bolts. Tighten the exhaust manifold heat shield 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 (1). Tighten the exhaust pipe to exhaust manifold bolts to 53 N.m (39 lb ft).
10. Install the wheelhouse panel.
11. Install the front tire and wheel, if necessary.
12. Lower the vehicle.

1. Remove the wheelhouse panel.
2. Remove the oil level indicator. 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.
5. Remove the exhaust gas recirculation (EGR) pipe nuts from the exhaust manifold.
6. Remove the EGR pipe bracket bolt.
7. Remove and discard the EGR pipe gasket.
8. Reposition the EGR pipe.
9. Raise and suitably support the vehicle with safety stands.
10. Remove the exhaust manifold heat shield bolts and nuts.
11. Remove the exhaust manifold heat shield.
12. Lower the vehicle.
13. Remove the exhaust manifold bolt and nuts.
14. Remove the exhaust manifold.
15. Remove and discard the exhaust manifold gasket.
16. Clean and inspect the exhaust manifold.

1. Install the a NEW exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolt and nuts. Tighten the exhaust manifold bolt to 35 N.m (26 lb ft). Tighten the exhaust manifold 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 the exhaust manifold heat shield bolts/nuts to 25 N.m (18 lb ft).
7. Lower the vehicle.
8. Position the EGR pipe.
9. Install a NEW EGR pipe gasket.
10. Install the EGR pipe bracket bolt. Tighten the EGR pipe bracket bolt to 50 N.m (37 lb ft).
11. Install the EGR pipe nuts to the exhaust manifold. Tighten the EGR pipe nuts to 30 N.m (22 lb ft).
12. Install the spark plugs. Important: Fully install the spark plug wires by pushing on the exposed end of the spark plug boot. Do not push the spark plug wire on to the spark plug by using the metal heat shield.
13. Install the spark plug wires to the spark plugs and ignition coils.
14. Install the oil level indicator.
15. Install the wheelhouse panel.

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1. Raise and suitably support the vehicle.
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 from the insulator.
6. Remove the exhaust manifold pipe from the vehicle.
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. Remove the right exhaust pipe to exhaust manifold (1) bolts.
10. Remove the lower bolt (2) retaining the heat shield to the exhaust outlet.
11. Lower the vehicle.
12. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).
13. Loosen the outlet duct clamp at the upper intake manifold cover.
14. Remove the upper intake manifold cover from the outlet duct.
15. Remove the upper intake manifold cover.
16. Remove the heat shield to turbocharger bolts.
17. Remove the turbocharger heat shield.
18. Remove the remaining bolts (1, and 3) for the exhaust outlet heat shield.
19. Remove the exhaust outlet heat shield.
20. Remove the turbocharger exhaust pipe bolts/nuts.
21. Remove the turbocharger exhaust pipe and gasket from the turbocharger.
22. Position the turbocharger exhaust pipe to the side in order to access the right exhaust pipe to turbocharger bolts. The turbocharger exhaust pipe cannot be removed until the right exhaust pipe is removed.
23. Remove the right exhaust pipe to turbocharger bolts (2).
24. Remove the right exhaust pipe and gaskets.
25. Remove the turbocharger exhaust pipe out the bottom of the vehicle.

1. From under the vehicle, position the turbocharger exhaust pipe to rear of the engine Do not install the pipe to the turbocharger.
2. Install the right exhaust pipe with NEW gasket to the turbocharger. Align the tabs on the gasket to face inward.
3. Install the exhaust pipe to turbocharger bolts (2). Tighten the exhaust pipe to turbocharger bolts to 53 N.m (39 lb ft).
4. Install the turbocharger exhaust pipe with a NEW gasket to the turbocharger.
5. Install the turbocharger exhaust pipe bolts/nuts. Tighten the turbocharger exhaust pipe bolts/nuts to 53 N.m (39 lb ft).
6. Install the turbocharger exhaust pipe heat shield.
7. Install the upper turbocharger exhaust pipe heat shield bolts (1, and 3). Tighten the turbocharger exhaust pipe heat shield bolts to 8 N.m (71 lb in).
8. Install the turbocharger heat shield.
9. Install the turbocharger heat shield bolts. Tighten the turbocharger heat shield bolts to 9 N.m (80 lb in).
10. Raise the vehicle.
11. Install the lower turbocharger exhaust pipe heat shield bolt (2). Tighten the turbocharger exhaust pipe heat shield bolt to 8 N.m (71 lb in).
12. If equipped with an automatic transmission, install the transmission fluid fill tube to bell housing nuts. Tighten the transmission fluid fill tube nuts 18 N.m (13 lb ft).
13. Install the right exhaust pipe to the exhaust manifold with a NEW gasket. Align the tab on the gasket to face outward as shown.
14. Install the right exhaust pipe to exhaust manifold bolts (1). Tighten the exhaust pipe to exhaust manifold bolts to 53 N.m (39 lb ft).
15. Install the exhaust manifold pipe hanger in the insulator.
16. Install the exhaust muffler to the exhaust manifold pipe.
17. Install the exhaust muffler nuts until snug.
18. Slide the exhaust pipe clamp down and around the pipe connection.
19. Tighten the exhaust pipe clamp. Tighten the exhaust manifold pipe clamp to 40 N.m (30 lb ft). Tighten the exhaust muffler nuts to 40 N.m (30 lb ft).
20. Lower the vehicle.
21. Install the upper intake manifold cover.
22. Install the upper intake manifold cover to the outlet duct.
23. Tighten the outlet duct clamp at the upper intake manifold cover. Tighten the clamp to 6 N.m (53 lb in).
24. Position the hood in the normal operating position by moving the hood hinge bolts from service position (2) to normal operating position (1). Tighten the hood hinge bolts to 25 N.m (18 lb ft).
25. Inspect for exhaust leaks.

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Scheme 33

1. Remove the exhaust muffler. Refer to «Muffler Replacement (4.3L, 4.8L & 5.3L Engines)»(ref-176276-S28282188752005050900000) or «Muffler Replacement (6.0L, 6.6L & 8.1L Engines)»(ref-176276-S21913993182005050900000) .
2. If equipped with a 6.0L or 8.1L engine, perform the following: 2.1. Remove the clip around the engine harness and the oxygen sensor pigtail. 2.2. Disconnect the connector position assurance (CPA) retainer. 2.3. Disconnect the oxygen sensor electrical connector. 2.4. If replacing the exhaust manifold pipe, remove the oxygen sensor.
3. If equipped with a 6.0L or 8.1L engine, remove the exhaust manifold pipe nuts.
4. If equipped with a 6.6L engine, remove the exhaust muffler nuts.
5. If equipped with a 6.6L engine, loosen the exhaust pipe clamp.
6. Slide the exhaust pipe clamp up onto the exhaust pipe adapter.
7. If equipped with a 6.0L or 8.1L engine, remove the exhaust manifold pipe.
8. Slide the exhaust manifold pipe hanger out of the exhaust pipe hanger bracket.
9. Discard the exhaust manifold pipe seal.
10. If equipped with a 6.6L engine, remove the exhaust manifold pipe.
11. 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 or 8.1L engine, 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 the 6.6L engine, install the exhaust muffler nuts until snug. Important: Ensure that the manifold pipe is square to the exhaust pipe adapter.
9. If equipped with a 6.6L engine, slide the exhaust pipe clamp down and around the pipe connection.
10. Tighten the exhaust pipe clamp and muffler nuts. Tighten the clamp to 40 N.m (30 lb ft). Tighten the nuts to 40 N.m (30 lb ft).
11. If equipped with a 6.0L or 8.1L engine, install the exhaust manifold pipe nuts. Tighten the nuts to 50 N.m (39 lb ft).
12. If equipped with a 6.0L or 8.1L engine, and the exhaust manifold pipe was replaced perform the following: 12.1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensor. 12.2. Install the old oxygen sensor. Tighten the oxygen sensor to 42 N.m (31 lb ft).
13. If equipped with a 6.0L or 8.1L engine, and the exhaust manifold pipe was not replaced perform the following: 13.1. Connect the oxygen sensor electrical connector. 13.2. Connect the CPA retainer. 13.3. Install the clip around the engine harness and the oxygen sensor pigtail.
14. Install the exhaust muffler. Refer to «Muffler Replacement (4.3L, 4.8L & 5.3L Engines)»(ref-176276-S28282188752005050900000) or «Muffler Replacement (6.0L, 6.6L & 8.1L Engines)»(ref-176276-S21913993182005050900000) .

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Scheme 35

1. Remove the turbocharger exhaust pipe. The turbocharger exhaust pipe does not need to be removed from the vehicle in order to remove the left exhaust pipe. Reposition the turbocharger exhaust pipe out of the way.
2. Remove the exhaust heat shield nuts (2) heat shield (3) from the dash panel.
3. Remove left exhaust pipe heat shield bolts.
4. Reposition the heat shield to the side in order to access the exhaust manifold to exhaust pipe bolts. Do not remove the heat shield at this time.
5. Remove the exhaust manifold to exhaust pipe bolts (2).
6. Remove and discard the gasket.
7. Lower the vehicle.
8. Remove the exhaust pipe heat shield. The shield will remove from the top of the engine.
9. Remove the exhaust pipe bolts (1) from the turbocharger.
10. Remove the exhaust pipe with the gasket.
11. Clean the exhaust pipe.
12. Clean the exhaust pipe mating surfaces.
13. Inspect the exhaust pipe for dents and cracks.
14. Replace the exhaust pipe if any damage is found.

1. Install the exhaust pipe with a NEW gasket to the turbocharger. Align the tab on the gasket at the turbocharger to face inward. To aid in installation temporarily install an exhaust pipe to exhaust manifold bolt.
2. Install the exhaust pipe to turbocharger bolts (1). Tighten the exhaust pipe to turbocharger bolts to 53 N.m (39 lb ft).
3. Install the exhaust pipe heat shield but do not install the bolts.
4. Raise the vehicle.
5. Install the exhaust pipe with a NEW gasket to the exhaust manifold. Align the tabs on the gasket to face outward.
6. Install the exhaust pipe to exhaust manifold bolts (2). Tighten the exhaust pipe to exhaust manifold bolts in 53 N.m (39 lb ft).
7. Install the exhaust pipe heat shield bolts. Tighten the exhaust pipe heat shield bolts to 8 N.m (71 lb in).
8. Install the left side exhaust heat shield (3) at the dash panel.
9. Install the heat shield nuts (2). Tighten the heat shield nuts to 9 N.m (80 lb in).
10. Install the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L Engine)»(ref-176276-S31782477922005050900000) .

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Scheme 37

1. Remove the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L Engine)»(ref-176276-S31782477922005050900000) . The turbocharger exhaust pipe does not need to be removed from the vehicle in order to access the right exhaust pipe. Reposition the turbocharger exhaust pipe out of the way.
2. Remove the exhaust gas recirculation (EGR) cooler tube nuts, from the studs (1).
3. Remove the exhaust pipe to the exhaust manifold bolts (1).
4. Remove the exhaust pipe to the turbocharger bolts (2).
5. Remove the right exhaust pipe and gaskets.
6. Clean the exhaust pipe.
7. Clean the exhaust pipe mating surfaces.
8. Inspect the exhaust pipe for dents and cracks.
9. Replace the exhaust pipe if any damage is found.

1. Install the right exhaust pipe with a NEW gasket to the turbocharger. Align the tab on the gasket to face inward.
2. Install the exhaust pipe to turbocharger bolts (2). Tighten the exhaust pipe to turbocharger bolts to 53 N.m (39 lb ft).
3. Install the exhaust pipe to the exhaust manifold with a NEW gasket. Align the tab on the gasket to face outward.
4. Install the exhaust pipe to exhaust manifold bolts (1). Tighten the exhaust pipe to exhaust manifold bolts to 53 N.m (39 lb ft).
5. Install the EGR cooler tube nuts, to the studs (1). Tighten the EGR cooler tube nuts to 30 N.m (22 lb ft).
6. Install the turbocharger exhaust pipe outlet. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L Engine)»(ref-176276-S31782477922005050900000) .

Scheme 38

1. Raise and suitably support the vehicle.
2. Remove the oil pan skid plate bolts and plate, if necessary.
3. 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.
4. 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).
5. If equipped with a 6.0L or 8.1L engine, perform the following Disconnect the CPA retainer. Disconnect the oxygen sensor electrical connector (1).
6. Support the catalytic converter or exhaust manifold pipe with adjustable jackstands.
7. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the left exhaust manifold pipe nuts.
8. If equipped with a 4.3L, 4.8L, or 5.3L engine, remove the right exhaust manifold pipe nuts.
9. If equipped with a 6.0L or 8.1L engine, remove the right exhaust manifold pipe nuts.
10. 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.
11. Lower the catalytic converter or exhaust manifold pipe using the adjustable jackstands.
12. 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 the transmission bolts to 100 N.m (74 lb ft). Tighten the exhaust pipe hanger bracket bolts to 12 N.m (106 lb in). Tighten the exhaust manifold pipe 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 the exhaust manifold pipe 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 the exhaust manifold pipe 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. Install the oil pan skid plate and bolts, if necessary. Tighten the oil pan skid plate bolts to 20 N.m (15 lb ft).
12. Lower the vehicle.

1. Raise and suitably support the vehicle.
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.

1. If necessary, install the oxygen sensors. 1.1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. 1.2. Install the oxygen sensors. Tighten the oxygen 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 sung.
5. Install the left exhaust manifold pipe nuts until snug.
6. Tighten the exhaust manifold pipe nuts. Tighten the exhaust manifold pipe nuts to 50 N.m (39 lb ft).
7. Install the exhaust muffler nuts. Tighten the exhaust muffler 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 39

1. Remove the muffler. Refer to «Muffler Replacement (4.3L, 4.8L & 5.3L Engines)»(ref-176276-S28282188752005050900000) or «Muffler Replacement (6.0L, 6.6L & 8.1L Engines)»(ref-176276-S21913993182005050900000) .
2. Remove the transmission support.
3. Disconnect the connector position assurance (CPA) retainers.
4. Disconnect the oxygen sensor electrical connectors (1, 2).
5. Remove the clip around the engine harness and oxygen sensor pigtail.
6. Disconnect the CPA retainer.
7. Disconnect the oxygen sensor electrical connector.
8. Remove the exhaust pipe hanger bracket bolts.
9. Remove the nuts attaching the insulator to the bracket.
10. Remove the insulator from the bracket.
11. Remove the right exhaust manifold pipe nuts.
12. Remove the left exhaust manifold pipe nuts.
13. Remove the left catalytic converter.
14. If equipped with a 6.0L engine, with regular production option (RPO) Y91, remove the left catalytic converter.
15. If equipped with a 6.0L engine, with RPO Y91, remove the right catalytic converter.
16. Remove the oxygen sensors if the catalytic converter(s) are to be replaced.

1. If the catalytic converter was replaced, perform the following: 1.1. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. 1.2. Install the oxygen sensors. Tighten the sensor to 42 N.m (31 lb ft).
2. If equipped with a 6.0L engine, with RPO Y91, install a NEW exhaust manifold pipe seal to the right catalytic converter.
3. Install the right catalytic converter.
4. If equipped with a 6.0L engine, with RPO Y91, install a NEW exhaust seal to the left catalytic converter.
5. Install the catalytic converter.
6. Install a NEW exhaust seal to the catalytic converter.
7. Install the catalytic converter.
8. Install the left exhaust manifold pipe nuts.
9. Tighten the right exhaust manifold pipe nuts. Tighten the nuts to 50 N.m (39 lb ft).
10. Install the insulator to the bracket.
11. Install the nuts attaching the insulator to the bracket. Tighten the nuts to 40 N.m (30 lb ft).
12. Install the exhaust pipe hanger bracket bolts. Tighten the bolts to 17 N.m (13 lb ft).
13. Connect the oxygen sensor electrical connector.
14. Connect the CPA retainer.
15. Install the clip around the engine harness and oxygen sensor pigtail.
16. Connect the oxygen sensor electrical connectors (1, 2).
17. Connect the CPA retainers.
18. Install the transmission support.
19. Install the muffler. Refer to «Muffler Replacement (4.3L, 4.8L & 5.3L Engines)»(ref-176276-S28282188752005050900000) or «Muffler Replacement (6.0L, 6.6L & 8.1L Engines)»(ref-176276-S21913993182005050900000) .

Scheme 40

1. Raise and suitably support the vehicle.
2. Remove the exhaust muffler hanger nuts.
3. Remove the hanger from the hanger insulator.

1. Install the hanger into the hanger insulator.
2. Install the exhaust muffler hanger nuts. Tighten the exhaust muffler hanger nuts to 50 N.m (39 lb ft).
3. Lower the vehicle.

Scheme 41

Scheme 42

Scheme 43

1. Remove the exhaust manifold pipe. Refer to «Exhaust Manifold Pipe Replacement (6.0L, 6.6L & 8.1L Engines)»(ref-176276-S28696987542005050900000) .
2. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (4.3L, 4.8L & 5.3L Engines)»(ref-176276-S21861646132005050900000) or «Catalytic Converter Replacement (6.0L & 8.1L Engines)»(ref-176276-S03440675272005050900000) .
3. If equipped with the 6.0L engine, and regular production option (RPO) MT1, remove the exhaust pipe hanger bracket bolts.
4. If equipped with the 6.0L or 8.1L engines, and RPO's MT1 (4-speed automatic transmission) and C5F/C6P, remove the exhaust pipe hanger bracket bolts.
5. If equipped with the 6.0L or 8.1L engines, and RPO's MW3 and C6P, remove the transmission bolts.
6. If equipped with the 6.0L engine, and RPO's MW3 and C6W, remove the exhaust pipe hanger bracket bolts.
7. If equipped with the 6.6L or 8.1L engines, and RPO M74, remove the exhaust pipe hanger bracket bolts.
8. If equipped with the 6.6L or 8.1L engines, and RPO ML6, remove the exhaust pipe hanger bracket bolts.
9. Remove the exhaust manifold pipe bracket.

1. Install the exhaust manifold pipe bracket.
2. If equipped with the 6.6L or 8.1L engines, and RPO M74, install the exhaust pipe hanger bracket bolts. Tighten the exhaust pipe hanger bracket bolts to 12 N.m (106 lb in).
3. If equipped with the 6.6L or 8.1L engines, and RPO ML6, install the exhaust pipe hanger bracket bolts. Tighten the exhaust pipe hanger bracket bolts to 12 N.m (106 lb in).
4. If equipped with the 6.0L engine, and RPO's MW3 and C6W, install the exhaust pipe hanger bracket bolts. Tighten the exhaust pipe hanger bracket bolts to 12 N.m (106 lb in).
5. If equipped with the 6.0L or 8.1L engines, and RPO's MW3 and C6P, install the transmission bolts. Tighten the transmission bolts to 100 N.m (74 lb ft).
6. If equipped with the 6.0L or 8.1L engines, and RPO's MT1 and C5F/C6P, install the exhaust pipe hanger bracket bolts. Tighten the exhaust pipe hanger bracket bolts to 12 N.m (106 lb in).
7. If equipped with the 6.0L engine, and RPO MT1, install the bracket bolts. Tighten the exhaust pipe hanger bracket bolts to 12 N.m (106 lb in).
8. Install the catalytic converter. Refer to «Catalytic Converter Replacement (4.3L, 4.8L & 5.3L Engines)»(ref-176276-S21861646132005050900000) or «Catalytic Converter Replacement (6.0L & 8.1L Engines)»(ref-176276-S03440675272005050900000) .
9. Install the exhaust manifold pipe. Refer to «Exhaust Manifold Pipe Replacement (6.0L, 6.6L & 8.1L Engines)»(ref-176276-S28696987542005050900000) .

1. Raise and suitably support the vehicle.
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 the exhaust muffler nuts to 40 N.m (30 lb ft).

Important: Depending on vehicle configuration, the rear axle may need to be lowered in order to remove the exhaust muffler assembly.

Scheme 44

Scheme 45

1. Raise and suitably support the vehicle.
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, perform the following: Unclip the oxygen sensor connector from the frame. Disconnect the connector position assurance (CPA) retainer. Disconnect the oxygen sensor electrical connector.
11. If equipped with a 6.0L or 8.1L engine, perform the following: Unclip the oxygen sensor connector from the support. Disconnect the CPA retainer. Disconnect the oxygen sensor electrical connector.
12. If equipped with a 6.0L or 8.1L engine, perform the following: Unclip the oxygen sensor connector from the support. Disconnect the CPA retainer. Disconnect the oxygen sensor electrical connector.
13. If equipped with a 6.0L engine, perform the following: Unclip the oxygen sensor connector from the frame. Disconnect the CPA retainer. Disconnect the oxygen sensor electrical connector.
14. If equipped with a 6.0L or 8.1L engine, remove the exhaust muffler nuts.
15. Loosen the exhaust pipe clamp.
16. With the aid of an assistant, support the exhaust muffler.
17. If equipped with a 6.6L engine, remove the exhaust muffler nuts.
18. With the aid of an assistant, support the exhaust muffler.
19. If equipped with a 6.0L or 8.1L engine, remove the insulators from the muffler hangers.
20. With the aid of an assistant, slide the muffler reward in order to separate the muffler from the catalytic converter.
21. Remove the insulators from the hangers, if necessary.
22. Remove the exhaust manifold pipe gasket. If necessary.
23. If equipped with a 6.0L engine, with regular production option (RPO) Y91, remove the insulator from the muffler hanger.
24. If equipped with a 6.0L engine, with RPO Y91, remove the insulators from the muffler hangers.
25. With the aid of an assistant, slide the muffler rearward in order to separate the muffler from the catalytic converter.
26. Remove the insulators from the hangers, if necessary.
27. Remove the exhaust manifold pipe gasket, if necessary.
28. If equipped with a 6.6L engine, remove the insulators from the muffler hangers.
29. With the aid of an assistant, slide the muffler rearward in order to separate the muffler from the exhaust muffler pipe.
30. Remove the insulators from the muffler hangers, if necessary.
31. Remove the exhaust muffler gasket, if necessary.
32. If equipped with a 6.0L or 8.1L engine, remove the oxygen sensor if the muffler is being replaced.

1. If equipped with a 6.0L or 8.1L engine, and the muffler was replaced re-install the old oxygen sensor.
2. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensor.
3. Install the oxygen sensor. Tighten the sensor to 42 N.m (31 lb ft). Important: Apply lubricant to the insulators to aid in installation.
4. If equipped with a 6.6L engine, install the insulators to the hangers, if necessary.
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 muffler hangers to the insulators. Important: Apply lubricant to the insulators to aid in installation.
8. If equipped with a 6.0L engine, with RPO Y91, install the insulators to the muffler hangers.
9. Install a new exhaust muffler gasket.
10. With the aid of an assistant, slide the muffler forward in order to install the muffler to the exhaust muffler pipe.
11. Install the insulators to the frame hangers.
12. If equipped with a 6.0L engine, with RPO Y91, install the insulator to the hanger. Important: Apply lubricant to the insulators to aid in installation.
13. If equipped with a 6.0L or 8.1L engine, install the insulators to the muffler hangers.
14. Install a new exhaust manifold pipe gasket.
15. With the aid of an assistant, slide the muffler forward in order to install the muffler to the catalytic converter.
16. Install the muffler hangers to the insulators.
17. If equipped with a 6.6L engine, install the exhaust muffler nuts. Tighten the nuts to 40 N.m (30 lb ft).
18. If equipped with a 6.0L or 8.1L engine, install the exhaust muffler nuts.
19. Tighten the exhaust pipe clamp bolt. Tighten the nuts to 40 N.m (30 lb ft). Tighten the clamp to 40 N.m (30 lb ft).
20. If equipped with a 6.0L engine, perform the following: Connect the oxygen sensor electrical connector. Connect the CPA retainer. Clip the oxygen sensor connector to the frame.
21. If equipped with a 6.0L or 8.1L engine, perform the following: Connect the oxygen sensor electrical connector. Connect the CPA retainer. Clip the oxygen sensor connector to the support.
22. If equipped with a 6.0L or 8.1L engine, perform the following: Connect the oxygen sensor electrical connector. Connect the CPA retainer. Clip the oxygen sensor connector to the support.
23. If equipped with a 6.0L or 8.1L engine, perform the following: Connect the oxygen sensor electrical connector. Connect the CPA retainer. Clip the oxygen sensor connector to the frame.
24. Raise the rear axle using the adjustable jack stands, if necessary.
25. Install the rear shock absorbers lower bolts and nuts, if necessary. Tighten the rear shock absorbers lower bolts to 95 N.m (70 lb ft).
26. If equipped with a 10.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
27. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
28. If equipped with a 8.6 or 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
29. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
30. Remove the adjustable jack stands from under the rear axle, if necessary.
31. Install the spare tire, if necessary.
32. Lower the vehicle.

Scheme 46

1. Remove the exhaust manifold pipe, if necessary. Refer to «Exhaust Manifold Pipe Replacement (6.0L, 6.6L & 8.1L Engines)»(ref-176276-S28696987542005050900000) .
2. Remove the catalytic converter, if necessary. Refer to «Catalytic Converter Replacement (4.3L, 4.8L & 5.3L Engines)»(ref-176276-S21861646132005050900000) or «Catalytic Converter Replacement (6.0L & 8.1L Engines)»(ref-176276-S03440675272005050900000) .
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 shield(s) from the studs.
11. If vehicle is a sport utility vehicle, remove the exhaust heat shield nuts.
12. Remove the exhaust heat shield from the studs.

1. If vehicle is a sport utility vehicle, install the exhaust heat shield to the studs.
2. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9N.m (80 lb in).
3. If vehicle is a crew cab pick-up truck, install the exhaust heat shield(s) to the studs.
4. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 N.m (80 lb in).
5. If vehicle is a extended cab pick-up truck, install the exhaust heat shield (1, 2) to the studs.
6. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 N.m (80 lb in).
7. 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.
8. Install the exhaust heat shield nuts. Tighten the exhaust heat shield nuts to 9 N.m (80 lb in).
9. Install the exhaust front heat shield to the studs.
10. install the exhaust front heat shield nuts. Tighten the exhaust heat shield nuts to 9 N.m (80 lb in).
11. Install the catalytic converter, if necessary. Refer to «Catalytic Converter Replacement (4.3L, 4.8L & 5.3L Engines)»(ref-176276-S21861646132005050900000) or «Catalytic Converter Replacement (6.0L & 8.1L Engines)»(ref-176276-S03440675272005050900000) .
12. Install the exhaust manifold pipe, if necessary. Refer to «Exhaust Manifold Pipe Replacement (6.0L, 6.6L & 8.1L Engines)»(ref-176276-S28696987542005050900000) .

Scheme 47

1. Remove the exhaust muffler. Refer to Muffler «Muffler Replacement (4.3L, 4.8L & 5.3L Engines)»(ref-176276-S28282188752005050900000) or «Muffler Replacement (6.0L, 6.6L & 8.1L Engines)»(ref-176276-S21913993182005050900000) .
2. If equipped with a 6 1/2 ft box, remove the exhaust heat shield bolts.
3. Remove the exhaust heat shield.
4. If equipped with a 8 ft box, remove the exhaust heat shield bolts.
5. Remove the exhaust heat shield.

1. If equipped with a 8 ft box, install the exhaust heat shield.
2. Install the exhaust heat shield bolts. Tighten 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 the exhaust heat shield bolts to 9 N.m (80 lb in).
5. Install the exhaust muffler. Refer to «Muffler Replacement (4.3L, 4.8L & 5.3L Engines)»(ref-176276-S28282188752005050900000) or «Muffler Replacement (6.0L, 6.6L & 8.1L Engines)»(ref-176276-S21913993182005050900000) .

Scheme 48

Scheme 49

1. Raise and suitably support the vehicle.
2. Remove the engine shield bolts and shield, if necessary.
3. Remove the exhaust heat shield nuts.
4. Remove the exhaust heat shield (1, 3) from the dash panel studs.

1. Install the exhaust heat shield (1, 3) to the dash panel studs.
2. Install the exhaust heat shield nuts. Tighten the nuts to 9 N.m (80 lb in).
3. Install the engine shield and bolts, if necessary. Tighten the bolts to 20 N.m (15 lb ft).
4. Lower the vehicle.