Engine Exhaust System: Removal & Installation Chevrolet SSR I

Removal Procedure

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the exhaust manifold pipe nuts.
3. Lower the vehicle.
4. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-187797-S28326354382005090100000) in Engine Controls - 4.8L, 5.3L, and 6.0L.
5. Remove the heat shield bolts (3) and shield (2) from the exhaust manifold (1).
6. Remove the exhaust manifold bolts, manifold, and gasket.
7. Discard the gasket.
8. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(ref-187833-S37411034902005090100000) in Engine Mechanical.

Installation Procedure

1. 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.
2. Install the exhaust manifold, NEW gasket and bolts. Tighten: 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. Tighten the exhaust manifold bolts a final 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.
3. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.
4. Install the heat shield (2) and bolts (3) to the exhaust manifold (1). Tighten: Tighten the exhaust manifold heat shield bolts to 9 N.m (80 lb in).
5. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-187797-S28326354382005090100000) in Engine Controls - 4.8L, 5.3L, and 6.0L.
6. Raise the vehicle.
7. Install the exhaust manifold pipe nuts. Tighten: Tighten the exhaust manifold pipe nuts to 50 N.m (37 lb ft).
8. Lower the vehicle.

Exhaust Manifold Replacement - Right

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove surge tank bolt and position surge tank aside. Refer to «Surge Tank Replacement»(ref-187839-S20635844932005090100000) in Engine Cooling.
3. Remove the exhaust manifold pipe nuts.
4. Lower the vehicle.
5. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-187797-S28326354382005090100000) in Engine Controls - 4.8L, 5.3L, and 6.0L.
6. Remove the heat shield bolts (1) and shield (2) from the exhaust manifold (1).
7. Remove the exhaust manifold bolts, manifold, and gasket.
8. Discard the gasket.
9. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(ref-187833-S37411034902005090100000) in Engine Mechanical.

1. 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.
2. Install the exhaust manifold, NEW gasket and bolts. Tighten: Tighten the exhaust manifold bolts a first 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. 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.
3. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.
4. Install the heat shield (2) and bolts (1) to the exhaust manifold (1). Tighten: Tighten the exhaust manifold heat shield bolts to 9 N.m (80 lb in).
5. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-187797-S28326354382005090100000) in Engine Controls - 4.8L, 5.3L, and 6.0L.
6. Install surge tank. Refer to «Surge Tank Replacement»(ref-187839-S20635844932005090100000) in Engine Cooling.
7. Raise the vehicle.
8. Install the exhaust manifold pipe nuts. Tighten: Tighten the exhaust manifold pipe nuts to 50 N.m (37 lb ft).
9. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the oil pan skid plate bolts and plate, if necessary.
3. 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. 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. Support the catalytic converter or exhaust manifold pipe with adjustable jackstands.
6. Remove the left exhaust manifold pipe nuts.
7. Remove the right exhaust manifold pipe nuts.
8. Lower the catalytic converter or exhaust manifold pipe using the adjustable jackstands.
9. 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. Install the right exhaust manifold pipe nuts.
4. Install the left exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
5. Remove the adjustable jackstands from catalytic converter or exhaust manifold pipe.
6. Perform the following: Connect the oxygen sensor electrical connector (1). Connect the CPA retainer. Clip the oxygen sensor electrical connector to the hose clip.
7. 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.
8. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Unclip the oxygen sensor connection from the floor reinforcement.
3. Remove the oxygen sensor clips from the frame.
4. Disconnect the connector position assurance (CPA) retainers.
5. Disconnect the oxygen sensor electrical connectors.
6. Unclip the oxygen sensors electrical connectors from the following: Hose clip Transmission crossmember
7. Disconnect the CPA retainers.
8. Disconnect the oxygen sensor electrical connectors (1, 2).
9. Remove the left exhaust manifold pipe nuts.
10. Remove the right exhaust manifold pipe nuts.
11. Remove the exhaust muffler nuts.
12. Remove the transmission support. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
13. Remove the catalytic converter.
14. If necessary, remove the oxygen sensors.

1. If necessary, install the oxygen sensors. Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors. NOTE: Refer to «Fastener Notice»(ref-187803-S24261752242005090100000) in Cautions and Notices. Install the oxygen sensors. Tighten: Tighten the sensors to 42 N.m (31 lb ft).
2. Install the catalytic convertor.
3. Install the transmission support. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
4. Install NEW exhaust manifold pipe seals to the exhaust manifolds.
5. Install the right exhaust manifold pipe nuts until snug.
6. Install the left exhaust manifold pipe nuts until snug.
7. Tighten the exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
8. Install the exhaust muffler nuts. Tighten: Tighten the nuts to 45 N.m (33 lb ft).
9. Connect the oxygen sensor electrical connectors (1, 2).
10. Connect the CPA retainers.
11. Clip the oxygen sensors electrical connectors to the following: Hose clip Transmission crossmember
12. Connect the oxygen sensor electrical connectors.
13. Connect the CPA retainers.
14. Install the clip around the engine harness and the oxygen sensor pigtail.
15. Clip the oxygen sensor connection to the floor reinforcement.
16. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the left rear tire assembly. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
3. Remove the left rear inner wheelwell housing. Refer to «Wheelhouse Liner Panel Replacement - Rear»(ref-187822-S11244346342005090100000) in Body Rear End.
4. Remove the rear fascia. Refer to «Fascia Replacement - Rear Bumper»(ref-187820-S32978763282005090100000) in Bumpers.
5. Support the left exhaust tail pipe with a suitable jack.
6. Remove the tail pipe insulator.
7. Scribe the location marks on the frame around the exhaust hanger bracket.
8. Grind off the heads of the rivets retaining exhaust hanger to frame.
9. Pry lightly on the exhaust hanger to remove from the frame.
10. Using a hammer or punch knock, rivet the stems into the frame.

1. Drill out holes on the frame using a 7/16 drill bit.
2. Transfer the hole location from the frame to the new exhaust hanger using the following procedure. Using a piece of paper, line up the edges with the scribe marks on the frame and mark location of the holes in the frame. Line up the edges of the paper on the new exhaust hanger making sure not to flip the paper and mark the hole location on the exhaust hanger. Drill out the hole on the exhaust hanger using a 7/16 drill bit.
3. Attach the exhaust hanger to the frame using the nut and bolts provided with the new hanger. Tighten: Tighten the bolts and nuts to 25 N.m (18 lb ft).
4. Install the tail pipe insulator.
5. Remove the support from the left exhaust tail pipe.
6. Install the rear fascia. Refer to «Fascia Replacement - Rear Bumper»(ref-187820-S32978763282005090100000) in Bumpers.
7. Install the left rear inner wheelwell housing. Refer to «Wheelhouse Liner Panel Replacement - Rear»(ref-187822-S11244346342005090100000) in Body Rear End.
8. Install the left rear tire assembly. Refer to «Tire and Wheel Removal and Installation»(ref-187818-S18654946232005090100000) in Tires and Wheels.
9. Adjust the exhaust hanger as necessary.
10. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Support the right side tail pipe with a suitable jack.
3. Remove the nuts retaining the right side exhaust insulator.
4. Lower the jack to gain clearance to remove the insulator.
5. Slide the exhaust insulator off the exhaust tail pipe hanger.
6. Remove the studs from the insulator bracket.
7. Remove the insulator bracket.

1. Install the insulator bracket.
2. Install the studs to the insulator bracket.
3. Slide the exhaust insulator on the exhaust tail pipe hanger.
4. Raise the jack that supports the tail pipe.
5. Install the nuts to retain the right side exhaust insulator.
6. Remove the jack that supports the tail pipe.
7. Align the tail pipes to fascia as necessary and then tighten the nuts. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
8. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the retaining nuts at the catalytic converter flange.
3. Remove the rear exhaust from the left adjustable hanger.
4. Remove right rear adjustable hanger nuts.
5. Remove the rear axle tie rod and axle brace from the rear axle. Refer to «Rear Axle Brace Replacement»(ref-187853-S34362054812005090100000) and «Rear Axle Tie Rod Replacement»(ref-187853-S03373958462005090100000) in Rear Suspension.
6. Remove the bolt retaining the right rear brake hose to the frame.
7. Remove the bolt retaining the right rear park brake cable to the frame.
8. Remove the frame brace by the gas tank. Refer to «Frame Brace Replacement»(ref-187823-S32793909542005090100000) in Frame and Underbody.
9. Remove the right rear stabilizer bar link.
10. Support the rear axle with a suitable jack.
11. Remove the right rear lower shock bolt.
12. Lower the axle to gain clearance to remove the exhaust.
13. Remove the right rear spring.
14. Remove the rear exhaust system from the insulators.
15. With the help of an assistant, remove the rear exhaust system from the vehicle.

1. With help of an assistant, install the rear exhaust system.
2. Install the rear exhaust system to the insulators.
3. Install the right rear spring.
4. Raise the rear axle.
5. Install the right rear lower shock bolt. Tighten: Tighten the bolt to 80 N.m (59 lb ft).
6. Remove the jack supporting the rear axle.
7. Install the right rear stabilizer link.
8. Install the frame brace by the gas tank. Refer to «Frame Brace Replacement»(ref-187823-S32793909542005090100000) in Frame and Underbody.
9. Install the bolt to retain the right rear park brake cable to frame. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
10. Install the bolt to retain the right rear brake hose to the frame. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
11. Install the rear axle tie rod and rear axle brace. Refer to «Rear Axle Brace Replacement»(ref-187853-S34362054812005090100000) and «Rear Axle Tie Rod Replacement»(ref-187853-S03373958462005090100000) in Rear Suspension.
12. Install the rear exhaust to the left adjustable hanger.
13. Install the nuts to retain the right exhaust hanger. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
14. Install the nuts at the catalytic converter flange. Tighten: Tighten the nuts to 45 N.m (33 lb ft).
15. Adjust the exhaust as necessary.
16. Lower the vehicle.

1. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-187797-S28326354382005090100000) in Engine Controls - 4.8L, 5.3L, and 6.0L.
2. Remove the heat shield bolts and shield from the exhaust manifold.

1. Install the heat shield and bolts to the exhaust manifold. Tighten: Tighten the nuts to 9 N.m (80 lb in).
2. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-187797-S28326354382005090100000) in Engine Controls - 4.8L, 5.3L, and 6.0L.

1. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-187797-S28326354382005090100000) in Engine Controls - 4.8L, 5.3L, and 6.0L.
2. Remove the heat shield bolts and shield from the exhaust manifold.

1. Install the heat shield and nuts to the exhaust manifold. Tighten: Tighten the nuts to 9 N.m (80 lb in).
2. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-187797-S28326354382005090100000) in Engine Controls - 4.8L, 5.3L, and 6.0L.