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Home/Chevrolet/Silverado 3500 HD/Chevrolet Silverado 3500 HD (2007-2012)/Repair manual/Exhaust/Engine Exhaust System: Removal & Installation
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Engine Exhaust System: Removal & Installation Chevrolet Silverado 3500 HD

Exhaust ~8874 words

Removal Procedure

  1. Install the J 42640 into the steering column lower access hole.
  2. Remove the left wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Left Side (Chevrolet)»(ref-317158-S07730931132009060900000) or «Front Wheelhouse Liner Replacement - Left Side (GMC)»(ref-317158-S30849864022009060900000) .
  3. Fully raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
  4. Remove the catalytic converter to exhaust manifold nuts. (1500 series shown, 2500 series similar).
  5. Lower the vehicle part way in order to work through the wheel opening.
  6. Remove the spark plug wires from the spark plugs. Twist the spark plug wire boot a 1/2 turn. Pull only on the boot in order to remove the wire from the spark plug.
  7. Remove the spark plug wires from the ignition coils. Twist the spark plug wire boot a 1/2 turn. Pull only on the boot in order to remove the wire from the ignition coil.
  8. Mark the relationship of the upper intermediate steering shaft to the steering column.
  9. Remove the steering shaft coupling bolt (2) and nut (1) from the upper intermediate steering shaft.
  10. Separate the upper intermediate steering shaft (3) from the steering column, position both shafts out of the way.
  11. Remove the exhaust manifold bolts, and exhaust manifold.
  12. Remove and discard the exhaust manifold gasket.
  13. Remove and discard the catalytic converter seal.
  14. If replacing the exhaust manifold, remove the exhaust manifold heat shield bolts, and shield from the exhaust manifold.

Installation Procedure

Note. 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 Diagnostic (OBD) II system performance. The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. Do not apply sealant to the first 3 threads of the bolt.

  1. If the exhaust manifold was replaced, position and install the exhaust manifold heat shield, and bolts to the exhaust manifold. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  2. Clean the threads of the exhaust manifold bolts.
  3. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts.
  4. Install a NEW catalytic converter seal to the catalytic converter.
  5. Position the NEW exhaust manifold gasket and exhaust manifold to the cylinder head.
  6. Ensure that the exhaust manifold is seated to the catalytic converter.
  7. Install the exhaust manifold bolts. Tighten: Tighten the 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. Tighten the bolts a final pass to 20 N.m (15 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
  8. Using a flat punch, bend the gasket tab at the rear of the gasket around the cylinder head edge.
  9. Position and align the marks on the upper intermediate steering shaft and the steering column.
  10. Install the upper intermediate steering shaft (3) to the steering column.
  11. Install the steering shaft coupling bolt (2) and nut (1) to the upper intermediate steering shaft. Tighten: Tighten the bolt/nut to 50 N.m (37 lb ft).
  12. Install the spark plug wires to the spark plugs.
  13. Install the spark plug wires to the ignition coils.
  14. Inspect the spark plug wires for proper installation. Push sideways on each boot in order to inspect the seating. Reinstall any loose boot.
  15. Fully raise and support the vehicle.
  16. Install the catalytic converter to exhaust manifold nuts. (1500 series shown, 2500 series similar). Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  17. Partially lower the vehicle.
  18. Install the left wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Left Side (Chevrolet)»(ref-317158-S07730931132009060900000) or «Front Wheelhouse Liner Replacement - Left Side (GMC)»(ref-317158-S30849864022009060900000) .
  19. Remove the J 42640 from the steering column lower access hole.
  1. Remove the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(ref-317156-S16775997122009060900000) .
  2. Remove the wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(ref-317158-S09176323932009060900000) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(ref-317158-S36351849782009060900000) .
  3. Perform the following steps working through the wheelhouse opening.
  4. Remove the steering coupling nut (1) and bolt (2) at the upper intermediate steering shaft.
  5. Separate the steering shaft coupling from the intermediate shaft.
  6. Remove the exhaust pipe to exhaust manifold bolts (1).
  7. Remove the exhaust manifold heat shield bolts (1) and shield (2).
  8. Remove the exhaust manifold bolts and nuts in the sequence shown.
  9. Remove the exhaust manifold and gasket. Discard the gasket.
  1. Install the a NEW exhaust manifold gasket onto the manifold studs.
  2. Position a NEW exhaust pipe gasket between the exhaust manifold and exhaust pipe. Align the tab on the gasket to face outward.
  3. Install the exhaust manifold onto the studs.
  4. Install and tighten the exhaust manifold bolts and nuts in the sequence shown to 57 N.m (42 lb ft).
  5. Tighten the 4 center bolts/nuts an additional pass to 57 N.m (42 lb ft)
  6. Install and tighten the exhaust pipe to exhaust manifold bolts in the sequence shown (1, 2, and 3) to 53 N.m (39 lb ft).
  7. Position the exhaust manifold heat shield (2) to the manifold and install the bolts (1) and tighten to 10 N.m (89 lb in).
  8. Install the steering shaft coupling to the intermediate shaft.
  9. Install the steering shaft coupling nut (1) and bolt (2) at the steering shaft coupling and tighten to 50 N.m (37 lb in).
  10. Install the wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(ref-317158-S09176323932009060900000) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(ref-317158-S36351849782009060900000) .
  11. Remove the charge air cooler inlet pipe. Refer to «Charge Air Cooler Inlet Pipe Replacement»(ref-317156-S16775997122009060900000) .
  12. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
  2. Remove the catalytic converter to exhaust manifold nuts (1).
  3. Lower the vehicle.
  4. Remove the exhaust manifold heat shield bolts and shield.
  5. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-317159-S10140370112009060900000) .
  6. Reposition the spark plug wires out of the way, if necessary.
  7. Remove the exhaust manifold bolts and stud.
  8. Remove the exhaust manifold and gaskets (1). Discard the gaskets.
  9. Remove the exhaust manifold to catalytic converter seal (2). Discard the seal.
  1. Install a NEW exhaust manifold to catalytic converter seal (2) into the relief in the catalytic converter.
  2. Place the exhaust manifold into position and install the manifold studs to the catalytic converter.
  3. Place the NEW exhaust manifold gaskets (1) between the manifold and the cylinder head.
  4. Install the exhaust manifold bolts and stud. Tighten: Tighten the bolts/stud to 30 N.m (22 lb ft).
  5. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-317159-S10140370112009060900000) .
  6. Position the exhaust manifold heat shield to the manifold and install the bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  7. Raise and support the vehicle.
  8. Install the catalytic converter to exhaust manifold nuts (1). Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  9. Lower the vehicle.
  1. Remove the heated oxygen sensor (HO2S). Refer to «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis)»(ref-317161-S23606000862009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series)»(ref-317161-S15120217592009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series)»(ref-317161-S10291002882009060900000) .
  2. Fully raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
  3. Remove the catalytic converter to exhaust manifold nuts, 1500 series shown, 2500 series similar.
  4. Remove the right wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(ref-317158-S09176323932009060900000) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(ref-317158-S36351849782009060900000) .
  5. Remove the spark plug wires (1) from the spark plugs. Twist the spark plug wire boot a 1/2 turn. Pull only on the boot in order to remove the wire from the spark plug.
  6. Remove the spark plug wires from the ignition coils. Twist the spark plug wire boot a 1/2 turn. Pull only on the boot in order to remove the wire from the ignition coil.
  7. Remove the oil level indicator tube bolt (419).
  8. Remove the oil level indicator tube (420) from the engine block.
  9. Remove the exhaust manifold bolts and exhaust manifold.
  10. Remove and discard the exhaust manifold gasket.
  11. Remove and discard the exhaust manifold seal.
  12. If replacing the exhaust manifold, remove the exhaust manifold heat shield bolts, and shield from the exhaust manifold.

Note. 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. Do not apply sealant to the first 3 threads of the bolt.

  1. If the exhaust manifold was replaced, position and install the exhaust manifold heat shield, and bolts to the exhaust manifold. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  2. Clean the threads of the exhaust manifold bolts.
  3. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts.
  4. Install a NEW catalytic converter seal to the exhaust manifold.
  5. Position the NEW exhaust manifold gasket and exhaust manifold to the cylinder head.
  6. Ensure that the catalytic converter seal is seated to the catalytic converter.
  7. Install the exhaust manifold bolts. Tighten: Tighten the 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. Tighten the bolts a final pass to 20 N.m (15 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
  8. Using a flat punch, bend the gasket tab at the rear of the gasket around the cylinder head edge.
  9. Inspect the O-ring seal (421) for cuts or damage, replace as necessary.
  10. Lubricate the O-ring seal (421) with clean engine oil.
  11. Install the oil level indicator tube (420) to the engine block.
  12. Install the oil level indicator tube bolt (419). Tighten: Tighten the bolt 25 N.m (18 lb ft).
  13. Install the spark plug wires (1) to the spark plugs.
  14. Install the spark plug wires to the ignition coils.
  15. Inspect the spark plug wires for proper installation. Push sideways on each boot in order to inspect the seating. Reinstall any loose boot.
  16. Install the right wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(ref-317158-S09176323932009060900000) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(ref-317158-S36351849782009060900000) .
  17. Fully raise and support the vehicle.
  18. Install the catalytic converter to exhaust manifold nuts, 1500 series shown, 2500 series similar. Tighten: Tighten the nuts to 50 N.m (37 lb ft). Partially lower the vehicle in order to work through the wheel opening. Install the HO2S. Refer to «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis)»(ref-317161-S23606000862009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series)»(ref-317161-S15120217592009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series)»(ref-317161-S10291002882009060900000) .
  1. Remove the wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(ref-317158-S09176323932009060900000) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(ref-317158-S36351849782009060900000) .
  2. Perform the following steps working through the wheelhouse opening, remove the exhaust pipe to turbocharger exhaust pipe bracket bolt.
  3. Remove the exhaust pipe to exhaust manifold bolts (1) and bracket.
  4. Remove the exhaust manifold heat shield bolts (1) and shield.
  5. Remove the exhaust manifold bolts and nuts in the proper sequence.
  6. Remove the exhaust manifold and exhaust manifold to pipe gasket.
  7. Remove the oil level indicator tube bolt (2) and rotate the oil level indicator tube out of the way.
  8. Remove and discard the exhaust manifold gasket (1).
  1. Install a NEW exhaust manifold gasket (1) onto the studs.
  2. Rotate the oil level indicator tube into position and install the oil level indicator tube bolt (2) and tighten to 21 N.m (15 lb ft).
  3. Position a NEW exhaust pipe gasket between the exhaust manifold and exhaust pipe. Align the tabs on the gasket to face downward.
  4. Install the exhaust manifold onto the studs.
  5. Install and tighten the exhaust manifold bolts and nuts in the sequence shown and tighten to 57 N.m (42 lb ft).
  6. Tighten the 4 center bolts/nuts an additional pass to 57 N.m (42 lb ft).
  7. Position the exhaust manifold heat shield to the manifold and install the exhaust manifold bolts (1) and tighten to 10 N.m (89 lb in).
  8. Install the exhaust pipe bracket and the exhaust pipe to exhaust manifold bolts (1).
  9. Tighten the exhaust pipe to exhaust manifold bolts in the sequence shown (4, 5, and 6) to 53 N.m (39 lb ft).
  10. Install the exhaust pipe to turbocharger exhaust pipe bracket bolt and tighten to 34 N.m (25 lb ft).
  11. Install the wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(ref-317158-S09176323932009060900000) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(ref-317158-S36351849782009060900000) .
  12. Lower the vehicle.
  1. Remove the heated oxygen sensor (HO2S). Refer to «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1»(ref-317159-S40073831782009060900000) .
  2. Remove the catalytic converter to exhaust manifold nuts (1).
  3. Lower the vehicle.
  4. Remove the exhaust manifold heat shield bolts and shield.
  5. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-317159-S10140370112009060900000) .
  6. Reposition the spark plug wires out of the way, if necessary.
  7. Remove the exhaust manifold bolts.
  8. Remove the exhaust manifold and gaskets (1). Discard the gaskets.
  9. Remove the exhaust manifold to catalytic converter seal (2). Discard the seal.
  1. Install a NEW exhaust manifold to catalytic converter seal (2) into the exhaust manifold.
  2. Place the exhaust manifold into position and install the manifold studs to the catalytic converter.
  3. Place the NEW exhaust manifold gaskets (1) between the manifold and the cylinder head.
  4. Install the exhaust manifold bolts and stud. Tighten: Tighten the bolts/stud to 30 N.m (22 lb ft).
  5. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-317159-S10140370112009060900000) .
  6. Position the exhaust manifold heat shield to the manifold and install the bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  7. Raise and support the vehicle.
  8. Install the catalytic converter to exhaust manifold nuts (1). Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  9. Lower the vehicle.
  1. Remove the glow plug control module and both brackets. Refer to «Glow Plug Control Module Replacement»(ref-317156-S37370146172009060900000) .
  2. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(ref-317156-S30403721302009060900000) .
  3. Remove the turbocharger upper heat shield bolts and shield.
  4. Loosen the turbocharger exhaust pipe to turbocharger clamp bolt (1).
  5. Remover the catalytic converter. Refer to «Catalytic Converter Replacement (With LU3)»(ref-317246-S00734019862009060900000) or «Catalytic Converter Replacement (With V8 Engine)»(ref-317246-S34260910422009060900000) or «Catalytic Converter Replacement (With LMM)»(ref-317246-S04006278602009060900000) .
  6. Perform the following steps working through the wheelhouse opening, Remove the transmission fluid fill tube to bellhousing nuts.
  7. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.
  8. Remove the turbocharger exhaust pipe heat shield bolts and shield.
  9. Remove the turbocharger exhaust pipe to bracket bolt (1).
  10. Remove the turbocharger exhaust pipe.
  1. Install the turbocharger exhaust pipe into the clamp and position the pipe flat against the turbocharger.
  2. Loosely install the turbocharger exhaust pipe to bracket bolt (1).
  3. Position the turbocharger exhaust pipe heat shield and install the heat shield bolts. Tighten: Tighten the bolts to 10 N.m (89 lb ft).
  4. Position the transmission fluid fill tube.
  5. Install the transmission fluid fill tube to bellhousing nuts. Tighten: Tighten the nuts to 18 N.m (13 lb ft).
  6. Tighten the turbocharger exhaust pipe to turbocharger clamp bolt (1). Tighten: Tighten the bolt to 15 N.m (11 lb ft).
  7. Install the catalytic converter. Refer to «Catalytic Converter Replacement (With LU3)»(ref-317246-S00734019862009060900000) , «Catalytic Converter Replacement (With V8 Engine)»(ref-317246-S34260910422009060900000) or «Catalytic Converter Replacement (With LMM)»(ref-317246-S04006278602009060900000) .
  8. Tighten the turbocharger exhaust pipe to bracket bolt. Tighten: Tighten the bolt to 34 N.m (25 lb ft).
  9. Install the turbocharger upper heat shield and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  10. Install the EGR valve cooler. Refer to «Exhaust Gas Recirculation Valve Cooler Replacement»(ref-317156-S30403721302009060900000) .
  11. Install the glow plug control module and both brackets. Refer to «Glow Plug Control Module Replacement»(ref-317156-S37370146172009060900000) .
  1. Remove the heated oxygen sensor (HO2S). Refer to «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis)»(ref-317161-S23606000862009060900000) , «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series)»(ref-317161-S15120217592009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series)»(ref-317161-S10291002882009060900000) .
  2. Support the transmission with a suitable transmission jack.
  3. Remove the transmission mount to transmission support nuts.
  4. Using the transmission jack, raise the transmission up off of the transmission support.
  5. Remove the transmission support crossmember bolts.
  6. Remove the transmission support crossmember.
  7. Remove the exhaust muffler to exhaust manifold pipe nuts (1).
  8. Remove the exhaust manifold pipe to exhaust manifold nuts.
  9. Using the transmission jack, lower the transmission slightly.
  10. Separate any necessary exhaust muffler insulators so that the pipe may be separated from the muffler.
  11. Remove the exhaust manifold pipe.
  12. Discard the exhaust manifold pipe gasket.
  1. Install a NEW exhaust manifold pipe gasket onto the muffler studs.
  2. Install the exhaust manifold pipe.
  3. Install any necessary exhaust muffler insulators that were separated from the muffler.
  4. Using the transmission jack, raise the transmission slightly.
  5. Install the exhaust manifold pipe to exhaust manifold nuts and tighten to 50 N.m (37 lb ft).
  6. Install the exhaust muffler to exhaust manifold pipe nuts (1) and tighten to 45 N.m (33 lb ft).
  7. Position the transmission support crossmember.
  8. Install the transmission support crossmember bolts and tighten to 95 N.m (70 lb ft).
  9. Using the transmission jack, lower the transmission onto the transmission support.
  10. Install the transmission mount to transmission support nuts and tighten to 40 N.m (30 lb ft).
  11. Remove the support from the transmission.
  12. Install the HO2S. Refer to «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis)»(ref-317161-S23606000862009060900000) , «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series)»(ref-317161-S15120217592009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series)»(ref-317161-S10291002882009060900000) .
  1. Remove the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L)»(ref-317246-S17326715162009060900000) .
  2. Remove the transmission. Refer to «Transmission Replacement»(ref-317209-S38287098042009060900000) .
  3. Remove the exhaust heat shield nuts (2) and heat shield (3) from the dash panel.
  4. Remove the exhaust pipe heat shield bolts and shield.
  5. Remove the exhaust pipe bolts in the sequence shown.
  6. Remove the exhaust pipe and gaskets. Discard the gaskets.
  1. Position the exhaust pipe with a NEW gasket to the turbocharger.
  2. Loosely install the exhaust pipe to turbocharger bolts.
  3. Position the exhaust pipe with a NEW gasket to the exhaust manifold. Align the tabs on the gasket to face downward.
  4. Loosely install the exhaust pipe to exhaust manifold bolts.
  5. Tighten the exhaust pipe bolts in the sequence shown to 53 N.m (39 lb ft).
  6. Install the exhaust pipe heat shield bolts and tighten to 10 N.m (89 lb in).
  7. Install the left side exhaust heat shield (3) at the dash panel.
  8. Install the heat shield nuts (2) and tighten to 9 N.m (80 lb in).
  9. Install the transmission. Refer to «Transmission Replacement»(ref-317209-S38287098042009060900000) .
  10. Install the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L)»(ref-317246-S17326715162009060900000) .
  1. Remove the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L)»(ref-317246-S17326715162009060900000) .
  2. Remove the upper exhaust gas recirculation cooling pipe. Refer to «Exhaust Gas Recirculation Cooling Pipe Replacement - Upper (LMM)»(ref-317133-S18845913752009060900000) .
  3. Remove the exhaust pipe bolts in the proper sequence.
  4. Remove the exhaust pipe, bracket and gaskets. Discard the gaskets.
  1. Position the exhaust pipe with a NEW gasket to the turbocharger.
  2. Loosely install the exhaust pipe to turbocharger bolts.
  3. Position the exhaust pipe with a NEW gasket to the exhaust manifold. Align the tabs on the gasket to face downward.
  4. Loosely install the exhaust pipe to exhaust manifold bolts.
  5. Tighten the exhaust pipe bolts in the sequence shown to 53 N.m (39 lb ft).
  6. Install the upper exhaust gas recirculation cooling pipe. Refer to «Exhaust Gas Recirculation Cooling Pipe Replacement - Upper (LMM)»(ref-317133-S18845913752009060900000) .
  7. Install the turbocharger exhaust pipe. Refer to «Turbocharger Exhaust Pipe Replacement (6.6L)»(ref-317246-S17326715162009060900000) .
  1. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (With LU3)»(ref-317246-S00734019862009060900000) or «Catalytic Converter Replacement (With V8 Engine)»(ref-317246-S34260910422009060900000) or «Catalytic Converter Replacement (With LMM)»(ref-317246-S04006278602009060900000) .
  2. Remove and discard the appropriate exhaust seal (1 or 2). (1500 series shown, 2500 series similar).
  1. Install the NEW appropriate exhaust seal (1 or 2). (1500 series shown, 2500 series similar).
  2. Install the catalytic converter. Refer to «Catalytic Converter Replacement (With LU3)»(ref-317246-S00734019862009060900000) or «Catalytic Converter Replacement (With V8 Engine)»(ref-317246-S34260910422009060900000) or «Catalytic Converter Replacement (With LMM)»(ref-317246-S04006278602009060900000) .
  1. Remove the left catalytic converter, if required. Refer to «Catalytic Converter Replacement - Left Side (With Cab Chassis)»(ref-317246-S36360260162009060900000) .
  2. Remove the exhaust manifold pipe, if required. Refer to «Exhaust Manifold Pipe Replacement»(ref-317246-S12798345982009060900000) .
  3. Remove and discard the appropriate exhaust seal (1) or gasket (2).
  1. Install the NEW appropriate exhaust seal (1) or gasket (2).
  2. Install the exhaust manifold pipe, if required. Refer to «Exhaust Manifold Pipe Replacement»(ref-317246-S12798345982009060900000) .
  3. Install the left catalytic converter, if required. Refer to «Catalytic Converter Replacement - Left Side (With Cab Chassis)»(ref-317246-S36360260162009060900000) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
  2. Remove the oil pan skid plate bolts and skid plate, if equipped.
  3. Remove the transmission crossmember. Refer to «Transmission Support Crossmember Replacement (2WD 1500/2500)»(ref-317158-S03701291012009060900000) or «Transmission Support Crossmember Replacement (4WD 1500/2500)»(ref-317158-S36944563212009060900000) or «Transmission Support Crossmember Replacement (2WD 2500 HD/3500)»(ref-317158-S03898872252009060900000) or «Transmission Support Crossmember Replacement (4WD 2500 HD/3500)»(ref-317158-S35822525892009060900000) .
  4. Remove the right front connector position assurance (CPA) retainer.
  5. Disconnect the right front heated oxygen sensor (HO2S) electrical connector (5) from the engine wiring harness electrical connector (4).
  6. Remove the right rear CPA retainer.
  7. Disconnect the engine wiring harness electrical connector (2) from the right rear HO2S electrical connector (1).
  8. Remove the right rear HO2S electrical connector clip from the engine harness clip (3).
  9. Remove the left rear CPA retainer.
  10. Disconnect the engine wiring harness electrical connector (1) from the left rear HO2S electrical connector (2).
  11. Remove the left rear HO2S electrical connector clip from the frame.
  12. For vehicles equipped with 2 wheel drive (2WD) perform the following steps, for vehicles equipped with 4 wheel drive (4WD) proceed to step 15.
  13. Remove the left front CPA retainer.
  14. Disconnect the left front HO2S electrical connector (7) from the engine wiring harness electrical connector (6).
  15. For vehicles equipped with 4WD perform the following steps, remove the left front CPA retainer.
  16. Disconnect the engine wiring harness electrical connector (7) from the left front HO2S electrical connector (8).
  17. Remove the left front HO2S electrical connector clip from the fuel line clip (2).
  18. Remove the catalytic converter to muffler nuts.
  19. Remove the catalytic converter to exhaust manifold nuts (1).
  20. Separate the catalytic converter assembly from the exhaust manifolds.
  21. Remove the catalytic converter assembly from the exhaust muffler.
  22. If replacing the catalytic converter assembly, perform the following steps, otherwise proceed to step 4 in the installation procedure.
  23. Remove the exhaust seals (2 and 3).
  24. Remove the HO2S (1-4) from the catalytic converter assembly.

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

  1. If replacing the catalytic converter assembly, perform the following steps, otherwise proceed to step 4.
  2. If reinstalling the old sensors, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
  3. Install the HO2S (1-4) to the catalytic converter assembly and tighten to 42 N.m (31 lb ft).
  4. Install the NEW exhaust seals (2 and 3) as required.
  5. Install the catalytic converter assembly to the muffler.
  6. Install the catalytic converter assembly to the exhaust manifolds.
  7. Install the catalytic converter to exhaust manifold nuts (1) and tighten to 50 N.m (37 lb ft).
  8. Install the catalytic converter to muffler nuts and tighten to 45 N.m (33 lb ft).
  9. For vehicles equipped with 4WD perform the following steps, for vehicles equipped with 2WD proceed to step 13.
  10. Connect the engine wiring harness electrical connector (6) to the left front HO2S electrical connector (7).
  11. Install the CPA retainer.
  12. Install the HO2S electrical connector clip to the fuel line clip (2).
  13. For vehicles equipped with 4WD perform the following steps, connect the engine wiring harness electrical connector (7) to the left front HO2S electrical connector (8).
  14. Install the left front CPA retainer.
  15. Connect the engine wiring harness electrical connector (1) to the left rear HO2S electrical connector (2).
  16. Install the left rear HO2S electrical connector clip to the frame.
  17. Install the CPA retainer.
  18. Connect the engine wiring harness electrical connector (2) to the right rear HO2S electrical connector (1).
  19. Install the right rear CPA retainer.
  20. Install the right rear HO2S electrical connector clip to the engine harness clip (3).
  21. Connect the right front HO2S electrical connector (5) to the engine wiring harness electrical connector (4).
  22. Install the right front CPA retainer.
  23. Install the transmission crossmember. Refer to «Transmission Support Crossmember Replacement (2WD 1500/2500)»(ref-317158-S03701291012009060900000) or «Transmission Support Crossmember Replacement (4WD 1500/2500)»(ref-317158-S36944563212009060900000) or «Transmission Support Crossmember Replacement (2WD 2500 HD/3500)»(ref-317158-S03898872252009060900000) or «Transmission Support Crossmember Replacement (4WD 2500 HD/3500)»(ref-317158-S35822525892009060900000) .
  24. Position the oil pan skid plate and install the oil pan skid plate bolts, if equipped and tighten to 28 N.m (21 lb ft).
  25. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
  2. Remove the oil pan skid plate bolts and skid plate, if equipped.
  3. Remove the transmission crossmember. Refer to «Transmission Support Crossmember Replacement (2WD 1500/2500)»(ref-317158-S03701291012009060900000) , «Transmission Support Crossmember Replacement (4WD 1500/2500)»(ref-317158-S36944563212009060900000) , «Transmission Support Crossmember Replacement (2WD 2500 HD/3500)»(ref-317158-S03898872252009060900000) or «Transmission Support Crossmember Replacement (4WD 2500 HD/3500)»(ref-317158-S35822525892009060900000) .
  4. Remove the right front connector position assurance (CPA) retainer (2).
  5. Disconnect the right front heated oxygen sensor (HO2S) electrical connector from the engine wiring harness electrical connector (1).
  6. Remove the right rear CPA retainer (4).
  7. Disconnect the engine wiring harness electrical connector (3) from the right rear HO2S electrical connector.
  8. Remove the right rear HO2S electrical connector clip from the engine harness clip (5).
  9. Remove the left rear CPA retainer (1).
  10. Disconnect the left rear HO2S electrical connector from the engine wiring harness electrical connector (3).
  11. For vehicles equipped with 2ML70 (2-Mode), unbolt harness retainer bracket. Unclip and reposition harness. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 15.
  12. Remove the left front CPA retainer.
  13. Disconnect the engine wiring harness electrical connector (2) from the left front HO2S.
  14. Remove the left front HO2S electrical connector clip (1) from the fuel line clip.
  15. Remove the left front CPA retainer (2).
  16. Remove the engine wiring harness electrical connector clip (1) from the fuel line clip.
  17. Disconnect the engine wiring harness electrical connector (3) from the left front HO2S.
  18. If the vehicle is a 1500 series, remove the catalytic converter to muffler nuts.
  19. If the vehicle is 2-Mode, loosen the clamp and disconnect the exhaust from the catalytic converter.
  20. If the vehicle is a 2500/3500 series, remove the muffler to catalytic converter nuts.
  21. Remove the HO2S. Refer to «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis)»(ref-317161-S23606000862009060900000) , «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series)»(ref-317161-S15120217592009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series)»(ref-317161-S10291002882009060900000) .
  22. Remove the catalytic converter to exhaust manifold nuts (1). (1500 series shown, 2500/3500 series similar).
  23. Separate the catalytic converter assembly from the exhaust manifolds.
  24. Remove the catalytic converter assembly from the exhaust muffler.
  25. If replacing the catalytic converter assembly, perform the following steps, otherwise proceed to step 4 in the installation procedure.
  26. Remove the exhaust seals (2 and 3).
  27. Remove the HO2S (1-5) from the catalytic converter assembly. (1500 series shown, 2500/3500 series similar).

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

  1. If replacing the catalytic converter assembly, perform the following steps, otherwise proceed to step 4.
  2. If reinstalling the old sensors, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
  3. Install the HO2S (1-5) to the catalytic converter assembly. (1500 series shown, 2500/3500 series similar) and tighten to 42 N.m (31 lb ft).
  4. Install the NEW exhaust seals (2 and 3) as required. (1500 series shown, 2500/3500 series similar).
  5. Install the catalytic converter assembly to the muffler.
  6. Install the catalytic converter assembly to the exhaust manifolds.
  7. Install the catalytic converter to exhaust manifold nuts (1) and tighten to 50 N.m (37 lb ft).
  8. Install the HO2S. Refer to «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis)»(ref-317161-S23606000862009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series)»(ref-317161-S15120217592009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series)»(ref-317161-S10291002882009060900000) .
  9. If the vehicle is a 2500/3500 series, install the muffler to catalytic converter nuts and tighten to 45 N.m (33 lb ft).
  10. If the vehicle is a 1500 series, install the catalytic converter to muffler nuts and tighten to 45 N.m (33 lb ft).
  11. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 13.
  12. Install the HO2S electrical connector clip (1) to the fuel line clip.
  13. Connect the engine wiring harness electrical connector (2) to the HO2S.
  14. Install the CPA retainer.
  15. Connect the engine wiring harness electrical connector (3) to the HO2S.
  16. Install the engine wiring harness electrical connector clip (1) to the fuel line clip.
  17. Install the CPA retainer (2).
  18. Connect the left rear HO2S electrical connector to the engine wiring harness electrical connector (3).
  19. Install the left rear CPA retainer (1).
  20. Install the right rear HO2S electrical connector clip to the engine harness clip (5).
  21. Connect the engine wiring harness electrical connector (3) to the right rear HO2S electrical connector.
  22. Install the right rear CPA retainer (4).
  23. Connect the right front HO2S electrical connector to the engine wiring harness electrical connector (1).
  24. Install the right front CPA retainer (2).
  25. Install the transmission crossmember. Refer to «Transmission Support Crossmember Replacement (2WD 1500/2500)»(ref-317158-S03701291012009060900000) or «Transmission Support Crossmember Replacement (4WD 1500/2500)»(ref-317158-S36944563212009060900000) or «Transmission Support Crossmember Replacement (2WD 2500 HD/3500)»(ref-317158-S03898872252009060900000) or «Transmission Support Crossmember Replacement (4WD 2500 HD/3500)»(ref-317158-S35822525892009060900000) .
  26. Position the oil pan skid plate and install the oil pan skid plate bolts, if equipped and tighten to 28 N.m (21 lb ft).
  27. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
  2. Support the transmission with a suitable transmission jack.
  3. Remove the transmission mount to transmission support nuts.
  4. Raise the transmission off of the transmission support.
  5. Remove the transmission support crossmember bolts.
  6. Remove the transmission support crossmember.
  7. Remove the catalytic converter to particulate filter nuts.
  8. Loosen the turbocharger exhaust pipe to catalytic converter clamp.
  9. Slide the clamp up onto the turbocharger exhaust pipe.
  10. Remove the catalytic converter.
  1. Apply water based lubricant to the exhaust pipe hanger bracket, in order to aid in installation.
  2. Install the catalytic converter.
  3. Slide the down turbocharger exhaust pipe to catalytic converter clamp.
  4. Tighten the turbocharger exhaust pipe to catalytic converter clamp to 12 N.m (106 lb in).
  5. Install the catalytic converter to particulate filter nuts and tighten to 45 N.m (33 lb ft).
  6. Install the transmission support crossmember.
  7. Install the transmission support crossmember bolts and tighten to 95 N.m (70 lb ft).
  8. Lower the transmission onto the transmission support.
  9. Install the transmission mount to transmission support nuts and tighten to 40 N.m (30 lb ft).
  10. Remove the support from the transmission.
  11. Lower the vehicle.
  1. Remove the exhaust temperature sensors. Refer to «Exhaust Temperature Sensor Replacement - Position 1»(ref-317156-S29488766162009060900000) and «Exhaust Temperature Sensor Replacement - Position 2»(ref-317156-S37678861942009060900000) .
  2. Remove the exhaust pressure differential sensor pipe. Refer to «Exhaust Pressure Differential Sensor Pipe Replacement (Pickup)»(ref-317156-S15095701602009060900000) or «Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis)»(ref-317156-S12371126482009060900000) .
  3. Remove the catalytic converter to exhaust particulate filter nuts (1).
  4. Remove the exhaust particulate filter hangers from the exhaust insulators (1).
  5. Remove the exhaust particulate filter (1).
  6. Remove and discard the catalytic converter to particulate filter gasket (2).
  1. Install a NEW gasket (2) onto the exhaust particulate filter studs.
  2. Install the exhaust particulate filter (1) to the catalytic converter.
  3. Install the exhaust particulate filter hangers to the exhaust insulators (1).
  4. Install the exhaust particulate filter to catalytic converter nuts (1) and tighten to 45 N.m (33 lb ft).
  5. Install the exhaust pressure differential sensor pipe. Refer to «Exhaust Pressure Differential Sensor Pipe Replacement (Pickup)»(ref-317156-S15095701602009060900000) or «Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis)»(ref-317156-S12371126482009060900000) .
  6. Install the exhaust temperature sensors. Refer to «Exhaust Temperature Sensor Replacement - Position 1»(ref-317156-S29488766162009060900000) and «Exhaust Temperature Sensor Replacement - Position 2»(ref-317156-S37678861942009060900000) .
  7. Using a scan tool, perform the DPF Reset For Replace DPF.
  1. Remove the exhaust temperature sensors. Refer to «Exhaust Temperature Sensor Replacement - Position 1»(ref-317156-S29488766162009060900000) and «Exhaust Temperature Sensor Replacement - Position 2»(ref-317156-S37678861942009060900000) .
  2. Remove the exhaust pressure differential sensor pipe. Refer to «Exhaust Pressure Differential Sensor Pipe Replacement (Pickup)»(ref-317156-S15095701602009060900000) or «Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis)»(ref-317156-S12371126482009060900000) .
  3. Remove the catalytic converter to exhaust particulate filter nuts (1).
  4. Remove the exhaust particulate filter hangers from the exhaust insulators (1).
  5. Remove the exhaust particulate filter (1).
  6. Remove and discard the catalytic converter to particulate filter gasket (2).
  1. Install a NEW gasket (2) onto the exhaust particulate filter studs.
  2. Install the exhaust particulate filter (1) to the catalytic converter.
  3. Install the exhaust particulate filter hangers to the exhaust insulators (1).
  4. Install the exhaust particulate filter to catalytic converter nuts (1). Tighten: Tighten the nuts to 45 N.m (33 lb ft).
  5. Install the exhaust pressure differential sensor pipe. Refer to «Exhaust Pressure Differential Sensor Pipe Replacement (Pickup)»(ref-317156-S15095701602009060900000) or «Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis)»(ref-317156-S12371126482009060900000) .
  6. Install the exhaust temperature sensors. Refer to «Exhaust Temperature Sensor Replacement - Position 1»(ref-317156-S29488766162009060900000) and «Exhaust Temperature Sensor Replacement - Position 2»(ref-317156-S37678861942009060900000) .
  7. Using a scan tool, perform the DPF Reset For Replace DPF.
  1. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (With LU3)»(ref-317246-S00734019862009060900000) or «Catalytic Converter Replacement (With V8 Engine)»(ref-317246-S34260910422009060900000) or «Catalytic Converter Replacement (With LMM)»(ref-317246-S04006278602009060900000) .
  2. Remove the exhaust temperature sensors. Refer to «Exhaust Temperature Sensor Replacement - Position 1»(ref-317156-S29488766162009060900000) and «Exhaust Temperature Sensor Replacement - Position 2»(ref-317156-S37678861942009060900000) .
  3. Remove the exhaust pressure differential sensor pipe. Refer to «Exhaust Pressure Differential Sensor Pipe Replacement (Pickup)»(ref-317156-S15095701602009060900000) or «Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis)»(ref-317156-S12371126482009060900000) .
  4. Remove the exhaust muffler to exhaust particulate filter nuts (1).
  5. Remove the exhaust particulate filter hangers from the exhaust insulators (1).
  6. Remove the exhaust particulate filter. (2500/3500 crew cab shown, regular/extended cabs similar).
  7. Remove and discard the exhaust particulate filter to muffler gasket.
  1. Install a NEW gasket onto the exhaust muffler studs.
  2. Install the exhaust particulate filter to the muffler studs.
  3. Install the exhaust particulate filter hangers to the exhaust insulators (1).
  4. Install the exhaust muffler to exhaust particulate filter nuts (1). Tighten: Tighten the nuts to 45 N.m (33 lb ft).
  5. Install the exhaust pressure differential sensor pipe. Refer to «Exhaust Pressure Differential Sensor Pipe Replacement (Pickup)»(ref-317156-S15095701602009060900000) or «Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis)»(ref-317156-S12371126482009060900000) .
  6. Install the exhaust temperature sensors. Refer to «Exhaust Temperature Sensor Replacement - Position 1»(ref-317156-S29488766162009060900000) and «Exhaust Temperature Sensor Replacement - Position 2»(ref-317156-S37678861942009060900000) .
  7. Install the catalytic converter. Refer to «Catalytic Converter Replacement (With LU3)»(ref-317246-S00734019862009060900000) or «Catalytic Converter Replacement (With V8 Engine)»(ref-317246-S34260910422009060900000) or «Catalytic Converter Replacement (With LMM)»(ref-317246-S04006278602009060900000) .
  8. Using a scan tool, perform the DPF Reset For Replace DPF.
  1. If equipped with a 6.0L engine, remove the exhaust manifold pipe. Refer to «Exhaust Manifold Pipe Replacement»(ref-317246-S12798345982009060900000) .
  2. If equipped with a 6.0L engine, remove the left catalytic converter. Refer to «Catalytic Converter Replacement - Left Side (With Cab Chassis)»(ref-317246-S36360260162009060900000) .
  3. If equipped with a 6.6L engine, remove the catalytic converter. Refer to «Catalytic Converter Replacement (With LU3)»(ref-317246-S00734019862009060900000) or «Catalytic Converter Replacement (With V8 Engine)»(ref-317246-S34260910422009060900000) or «Catalytic Converter Replacement (With LMM)»(ref-317246-S04006278602009060900000) .
  4. If equipped with a 4L80-E automatic transmission, regular production option (RPO) MT1, remove the exhaust pipe hanger bracket bolts and bracket.
  5. If equipped with a Allison® automatic transmission, RPO MW7, remove the exhaust pipe hanger bracket bolt/stud and bracket.
  6. If equipped with a 6L90-E automatic transmission, RPO MYD, remove the exhaust pipe hanger bracket bolts and bracket.
  1. If equipped with a 6L90-E automatic transmission, RPO MYD, install the exhaust pipe hanger bracket and bolts and tighten to 25 N.m (18 lb ft).
  2. If equipped with a Allison® automatic transmission, RPO MW7, install the exhaust pipe hanger bracket and bolt/stud and tighten to 25 N.m (18 lb ft).
  3. If equipped with a 4L80-E automatic transmission, RPO MT1, install the exhaust pipe hanger bracket and bolts and tighten to 25 N.m (18 lb ft).
  4. If equipped with a 6.6L engine, install the catalytic converter. Refer to «Catalytic Converter Replacement (With LU3)»(ref-317246-S00734019862009060900000) or «Catalytic Converter Replacement (With V8 Engine)»(ref-317246-S34260910422009060900000) or «Catalytic Converter Replacement (With LMM)»(ref-317246-S04006278602009060900000) .
  5. If equipped with a 6.0L engine, install the left catalytic converter. Refer to «Catalytic Converter Replacement - Left Side (With Cab Chassis)»(ref-317246-S36360260162009060900000) .
  6. If equipped with a 6.0L engine, install the exhaust manifold pipe. Refer to «Exhaust Manifold Pipe Replacement»(ref-317246-S12798345982009060900000) .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
  2. Lower the spare tire.
  3. Remove the catalytic converter to exhaust muffler nuts.
  4. If equipped with a 4.8L engine, perform the following steps, otherwise proceed to step 7.
  5. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease removal.
  6. With the aid of an assistant, remove the insulators (1, 2) from the front and rear muffler assembly hangers.
  7. Remove the insulator (1) from the intermediate muffler assembly hanger and remove the muffler assembly.
  8. If equipped with a 5.3L, or a 6.0L engine, perform the following steps.
  9. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease removal.
  10. With the aid of an assistant, remove the insulators (1, 2) from the front and rear muffler assembly hangers.
  11. Remove the insulators (1) from the intermediate muffler assembly hangers and remove the muffler assembly. Pull the muffler assembly rearward until the flange is able to clear the front frame crossmember, and remove the muffler toward the front of the vehicle.
  1. If equipped with a 4.8L engine, perform the following steps, otherwise proceed to step 6.
  2. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease installation.
  3. With the aid of an assistant, position and install the muffler assembly.
  4. Install the insulators (1, 2) to the front and rear muffler assembly hangers.
  5. Install the insulator (1) to the intermediate muffler assembly hanger.
  6. If equipped with a 5.3L, or a 6.0L engine, perform the following steps.
  7. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease installation.
  8. With the aid of an assistant, position and install the muffler assembly.
  9. Install the insulators (1, 2) to the front and rear muffler assembly hangers.
  10. Install the insulator (1) to the intermediate muffler assembly hanger.
  11. Install the catalytic converter to exhaust muffler nuts and tighten to 45 N.m (33 lb ft).
  12. Return the spare tire to the original position.
  13. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
  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 a 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 absorber lower bolts and nuts, if necessary.
  9. Lower the rear axle using the adjustable jack stands, if necessary.
  10. Remove the catalytic converter to muffler nuts.
  11. Lubricate the 5 insulators where the muffler assembly hangers are inserted in order to ease removal.
  12. With the aid of an assistant, remove the insulators (1-3) from the front, intermediate and rear muffler assembly hangers.
  13. Remove the insulator (1) from the tail pipe hanger and remove the muffler assembly.
  1. Lubricate the 5 insulators where the muffler assembly hangers are inserted in order to ease installation.
  2. With the aid of an assistant, position and install the muffler assembly.
  3. Install the insulator (1) to the rear tail pipe hanger.
  4. Install the insulators (1-3) to the front, intermediate, and rear muffler assembly hangers.
  5. Install the catalytic converter to muffler nuts and tighten to 45 N.m (33 lb ft).
  6. Raise the rear axle using the adjustable jack stands, if necessary.
  7. Install the rear shock absorber lower bolts and nuts, if necessary and tighten to 95 N.m (70 lb ft).
  8. If equipped with a 10.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  9. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  10. If equipped with a 8.6 or a 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  11. Install the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  12. Remove the adjustable jack stands from under the rear axle, if necessary.
  13. Install the spare tire, if necessary.
  14. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
  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 a 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 absorber lower bolts and nuts, if necessary.
  9. Lower the rear axle using the adjustable jack stands, if necessary.
  10. Remove the muffler to catalytic converter nuts.
  11. If the vehicle is a non heavy duty (HD), perform the following steps, otherwise proceed to step 14
  12. Lubricate the 4 insulators where the muffler assembly hangers are inserted in order to ease removal.
  13. With the aid of an assistant, remove the insulators (1-4) from the front, intermediate, and rear muffler assembly hangers and remove the muffler assembly.
  14. If the vehicle is a heavy duty (HD) perform the following steps
  15. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease removal.
  16. With the aid of an assistant, remove the insulators (1-3) from the front, intermediate, and rear muffler assembly hangers and remove the muffler assembly.
  1. If the vehicle is a non HD, perform the following steps, otherwise proceed to step 5
  2. Lubricate the 4 insulators where the muffler assembly hangers are inserted in order to ease installation.
  3. With the aid of an assistant, position and install the muffler assembly.
  4. Install the insulators (1-4) to the front, intermediate, and rear muffler assembly hangers.
  5. If the vehicle is a HD, perform the following steps
  6. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease installation.
  7. With the aid of an assistant, position and install the muffler assembly.
  8. Install the insulators (1-3) to the front, intermediate, and rear muffler assembly hangers.
  9. Install the catalytic converter to exhaust muffler nuts and tighten to 45 N.m (33 lb ft).
  10. Raise the rear axle using the adjustable jack stands, if necessary.
  11. Install the rear shock absorber lower bolts and nuts, if necessary and tighten to 95 N.m (70 lb ft).
  12. If equipped with a 10.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  13. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  14. If equipped with a 8.6 or a 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  15. Install the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  16. Remove the adjustable jack stands from under the rear axle, if necessary.
  17. Install the spare tire, if necessary.
  18. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
  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 a 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 absorber lower bolts and nuts, if necessary.
  9. Lower the rear axle using the adjustable jack stands, if necessary.
  10. Remove the exhaust muffler to exhaust manifold pipe nuts (1).
  11. Loosen the exhaust muffler clamp (3).
  12. Remove the heated oxygen sensor (HO2S). Refer to «Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series - Cab/Chassis)»(ref-317161-S31963179192009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series)»(ref-317161-S09983562602009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series)»(ref-317161-S09703662922009060900000) .
  13. Lubricate the 4 insulators where the muffler assembly hangers are inserted in order to ease removal.
  14. With the aid of an assistant, remove the insulators (1-4) from the front, intermediate, and rear muffler assembly hangers and remove the muffler assembly.
  1. Lubricate the 4 insulators where the muffler assembly hangers are inserted in order to ease installation.
  2. With the aid of an assistant, position and install the muffler assembly.
  3. Install the insulators (1-4) to the front, intermediate, and rear muffler assembly hangers.
  4. Install the HO2S. Refer to «Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series - Cab/Chassis)»(ref-317161-S31963179192009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series)»(ref-317161-S09983562602009060900000) or «Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series)»(ref-317161-S09703662922009060900000) .
  5. Tighten the exhaust muffler clamp (3) to 47 N.m (35 lb ft).
  6. Install the exhaust muffler to exhaust manifold pipe nuts (1) and tighten to 45 N.m (33 lb ft).
  7. Raise the rear axle using the adjustable jack stands, if necessary.
  8. Install the rear shock absorber lower bolts and nuts, if necessary and tighten to 95 N.m (70 lb ft).
  9. If equipped with a 10.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  10. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  11. If equipped with a 8.6 or a 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary.
  12. Install the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  13. Remove the adjustable jack stands from under the rear axle, if necessary.
  14. Install the spare tire, if necessary.
  15. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
  2. Remove the spare tire, if necessary.
  3. Install adjustable jack stands under the rear axle, if necessary.
  4. 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. Remove the rear shock absorbers lower bolts and nuts, if necessary.
  7. Lower the rear axle using the adjustable jack stands, if necessary.
  8. Remove the exhaust muffler to exhaust particulate filter nuts (1).
  9. With the aid of an assistant, support the exhaust muffler.
  10. Remove the exhaust muffler hangers from the exhaust insulators (1).
  11. Remove the exhaust muffler. (2500/3500 crew cab shown, regular/extended cabs similar).
  12. Remove and discard the exhaust particulate filter to muffler gasket.
  1. Install a NEW gasket onto the exhaust muffler studs.
  2. Install the exhaust muffler to the particulate filter.
  3. With the aid of an assistant, support the exhaust muffler.
  4. Install the exhaust muffler hangers to the exhaust insulators (1).
  5. Install the exhaust muffler to exhaust particulate filter nuts (1) and tighten to 45 N.m (33 lb ft).
  6. Raise the rear axle using the adjustable jack stands, if necessary.
  7. Install the rear shock absorbers lower bolts and nuts, if necessary and tighten to 95 N.m (70 lb ft).
  8. Install the rear axle vent hose to the rear axle, if necessary.
  9. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary.
  10. Remove the adjustable jack stands from under the rear axle, if necessary.
  11. Install the spare tire, if necessary.
  12. Lower the vehicle.
  1. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (With LU3)»(ref-317246-S00734019862009060900000) or «Catalytic Converter Replacement (With V8 Engine)»(ref-317246-S34260910422009060900000) or «Catalytic Converter Replacement (With LMM)»(ref-317246-S04006278602009060900000) .
  2. If vehicle has a regular cab, remove the exhaust heat shield nuts.
  3. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs.
  4. If vehicle has extended cab, remove the exhaust heat shield nuts.
  5. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs.
  6. If vehicle has a crew cab, remove the exhaust heat shield nuts.
  7. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs.
  1. If vehicle has a crew cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the underbody studs.
  2. Install the exhaust heat shield nuts and tighten to 9 N.m (80 lb in).
  3. If vehicle has a extended cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the underbody studs.
  4. Install the exhaust heat shield nuts and tighten to 9 N.m (80 lb in).
  5. If vehicle has a regular cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the studs.
  6. Install the exhaust heat shield nuts and tighten to 9 N.m (80 lb in).
  7. Install the catalytic converter. Refer to «Catalytic Converter Replacement (With LU3)»(ref-317246-S00734019862009060900000) or «Catalytic Converter Replacement (With V8 Engine)»(ref-317246-S34260910422009060900000) or «Catalytic Converter Replacement (With LMM)»(ref-317246-S04006278602009060900000) .
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-317166-S17709202752009060900000) .
  2. Remove the exhaust heat shield nuts.
  3. Remove both wheelhouse panels. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(ref-317158-S09176323932009060900000) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(ref-317158-S36351849782009060900000) and «Front Wheelhouse Liner Replacement - Left Side (Chevrolet)»(ref-317158-S07730931132009060900000) or «Front Wheelhouse Liner Replacement - Left Side (GMC)»(ref-317158-S30849864022009060900000) .
  4. Remove the exhaust heat shield (1, 3) from the dash panel studs.
  5. Remove the heat shield (1, 3) through the respective wheelwell.
  1. Install the heat shields (1, 3) through the respective wheelwell.
  2. Install the exhaust heat shield (1, 3) to the dash panel studs.
  3. Install the exhaust heat shield nuts and tighten to 9 N.m (80 lb in).
  4. Lower the vehicle.
  1. Remove the right wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(ref-317158-S09176323932009060900000) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(ref-317158-S36351849782009060900000) .
  2. Remove the exhaust manifold heat shield bolts and heat shield from the exhaust manifold.
  1. Position the exhaust manifold heat shield to the exhaust manifold and install the heat shield bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  2. Install the right wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(ref-317158-S09176323932009060900000) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(ref-317158-S36351849782009060900000) .
  1. Remove the spark plug wires. Refer to «Spark Plug Replacement»(ref-317161-S06538676822009060900000) .
  2. Reposition the spark plug wires out of the way, if necessary.
  3. Remove the exhaust manifold heat shield bolts and heat shield from the exhaust manifold.
  1. Position the exhaust manifold heat shield to the exhaust manifold and install the heat shield bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  2. Install the spark plug wires. Refer to «Spark Plug Replacement»(ref-317161-S06538676822009060900000) .
  1. Remove the spark plug wires. Refer to «Spark Plug Replacement»(ref-317161-S06538676822009060900000) .
  2. Reposition the spark plug wires out of the way, if necessary.
  3. Remove the exhaust manifold heat shield bolts and heat shield from the exhaust manifold.
  1. Position the exhaust manifold heat shield to the exhaust manifold and install the heat shield bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  2. Install the spark plug wires. Refer to «Spark Plug Replacement»(ref-317161-S06538676822009060900000) .
  1. Remove the right wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(ref-317158-S09176323932009060900000) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(ref-317158-S36351849782009060900000) .
  2. Remove the exhaust manifold heat shield bolts and heat shield from the exhaust manifold.
  1. Position the exhaust manifold heat shield to the exhaust manifold and install the heat shield bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  2. Install the right wheelhouse liner. Refer to «Front Wheelhouse Liner Replacement - Right Side (Chevrolet)»(ref-317158-S09176323932009060900000) or «Front Wheelhouse Liner Replacement - Right Side (GMC)»(ref-317158-S36351849782009060900000) .

More articles — Engine Exhaust System