Engine Exhaust System: Removal & Installation Chevrolet Uplander I

Removal Procedure

1. Remove the throttle body air inlet duct. Refer to «AIR CLEANER INTAKE DUCT REPLACEMENT»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L.
2. Drain the engine coolant from the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) in Engine Cooling.
3. Remove the right engine mount strut bracket. Refer to «ENGINE MOUNT STRUT BRACKET REPLACEMENT - LEFT»(ref-241709-S10798600442006081100000) in Engine Mechanical - 3.5L.
4. Disconnect the inlet radiator hose from the engine. Refer to «RADIATOR HOSE REPLACEMENT - INLET»(ref-241700-S17953640892006081100000) in Engine Cooling.
5. Remove the thermostat bypass pipe. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT - LX9 (3.5L)»(ref-241700-S05879389552007022300000) in Engine Cooling.
6. Remove the exhaust crossover pipe bolts from the engine left side exhaust manifold. Refer to «Exhaust Crossover Pipe Replacement»(ref-241745-S33460791922007022700000) .
7. Remove the exhaust manifold heat shield bolts.
8. Remove the exhaust manifold heat shield.
9. Remove the exhaust manifold nuts.
10. Remove the exhaust manifold.
11. Remove the exhaust manifold gasket.
12. Clean the engine left side exhaust manifold to the engine left side cylinder head sealing surfaces.

Installation Procedure

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold nuts. Tighten: Tighten the exhaust manifold nuts to 16 N.m (12 lb ft).
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
6. Install the exhaust crossover pipe. Refer to «Exhaust Crossover Pipe Replacement»(ref-241745-S33460791922007022700000) .
7. Install the thermostat bypass pipe. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT - LX9 (3.5L)»(ref-241700-S05879389552007022300000) in Engine Cooling.
8. Connect the inlet radiator hose to the engine. Refer to «RADIATOR HOSE REPLACEMENT - INLET»(ref-241700-S17953640892006081100000) in Engine Cooling.
9. Install right engine mount strut bracket. Refer to «ENGINE MOUNT STRUT BRACKET REPLACEMENT - RIGHT»(ref-241709-S05394895052006081100000) in Engine Mechanical - 3.5L.
10. Fill engine coolant from the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) in Engine Cooling.
11. Install throttle body air inlet duct. Refer to «AIR CLEANER INTAKE DUCT REPLACEMENT»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L.

Scheme 1

1. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
2. Remove the right engine mount strut bracket. Refer to «ENGINE MOUNT STRUT REPLACEMENT - LEFT»(ref-241744-S13621555592006081100000) .
3. Remove the radiator inlet hose. Refer to «RADIATOR HOSE REPLACEMENT - INLET»(ref-241700-S17953640892006081100000) .
4. Disconnect the heater hoses from the heater pipes.
5. Remove the nuts holding the heater pipes on the throttle body.
6. Position the heater pipes aside.
7. Remove the exhaust crossover heat shield bolts (1) and shield (2).
8. Remove the exhaust crossover pipe (2) to left exhaust manifold nuts.
9. Remove the exhaust manifold heat shield bolts.
10. Remove the exhaust manifold heat shield.
11. Remove the exhaust manifold bolts.
12. Remove the exhaust manifold.
13. Remove the exhaust manifold gasket.

1. Position a NEW exhaust manifold gasket to the cylinder head.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts. Tighten: Tighten the exhaust manifold nuts to 20 N.m (15 lb ft).
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold nuts to 10 N.m (89 in ft).
6. Install the exhaust crossover pipe (2) to left exhaust manifold nuts. Tighten: Tighten the exhaust manifold nuts to 20 N.m (15 lb ft).
7. Position the heater pipes back and connect hoses.
8. Install the nuts holding the heater pipe to the throttle body.
9. Install the hose clamps to the heater pipes and hose.
10. Install the exhaust crossover heat shield (2) and bolts (1). Tighten: Tighten the exhaust manifold nuts to 10 N.m (89 in ft).
11. Install the radiator inlet hose. Refer to «RADIATOR HOSE REPLACEMENT - INLET»(ref-241700-S17953640892006081100000) .
12. Install the right engine mount strut bracket. Refer to «ENGINE MOUNT STRUT REPLACEMENT - LEFT SIDE»(ref-241744-S13621555592006081100000) .
13. Install air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .

1. Remove the throttle body air inlet duct. Refer to «AIR CLEANER INTAKE DUCT REPLACEMENT»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L.
2. Rotate the engine for service access. Refer to «ROTATING THE ENGINE FOR SERVICE ACCESS»(ref-241709-S15570154112006081100000) in Engine Mechanical - 3.5L.
3. Remove the manifold air pressure (MAP) sensor. Refer to «MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT»(ref-241686-S05170885732006081100000) in Engine Controls - 3.5L.
4. Remove the exhaust gas recirculation (EGR) valve. Refer to «EXHAUST GAS RECIRCULATION (EGR) VALVE REPLACEMENT»(ref-241686-S32798936942006081100000) in Engine Controls - 3.5L.
5. Remove the ignition module and the ignition coils with the bracket. Refer to «IGNITION CONTROL MODULE REPLACEMENT»(ref-241686-S35343301302006081100000) in Engine Controls - 3.5L.
6. Remove the spark plug wires from the engine right bank spark plugs. Refer to «SPARK PLUG WIRE REPLACEMENT»(ref-241686-S08152444132006081100000) in Engine Controls - 3.5L.
7. Disconnect the oxygen sensor electrical connector. Refer to «HEATED OXYGEN SENSOR REPLACEMENT - POSITION 1»(ref-241686-S22936041462006081100000) in Engine Controls - 3.5L.
8. Remove the exhaust crossover pipe bolts from the engine left side exhaust manifold. Refer to «Exhaust Crossover Pipe Replacement»(ref-241745-S33460791922007022700000) .
9. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-241684-S36257494482006081100000) in General Information.
10. Remove the catalytic converter. Refer to «Catalytic Converter Replacement»(ref-241745-S34308852242007022700000) .
11. Remove the exhaust manifold heat shield bolts.
12. Remove the exhaust manifold heat shields.
13. Remove the exhaust manifold nuts.
14. Remove the exhaust manifold.
15. Remove the exhaust manifold gasket.
16. Lower the vehicle.
17. Clean the engine right side exhaust manifold sealing surfaces and the cylinder head sealing surfaces.
18. If you are REPLACING the engine right side exhaust manifold, remove the EGR valve pipe. Refer to «EXHAUST GAS RECIRCULATION (EGR) PIPE REPLACEMENT»(ref-241686-S02817433772006081100000) in Engine Controls - 3.5L.
19. If you are REPLACING the engine right side exhaust manifold, remove the heated oxygen sensor (HO2S). Refer to «HEATED OXYGEN SENSOR REPLACEMENT - POSITION 1»(ref-241686-S22936041462006081100000) in Engine Controls - 3.5L.

1. If removed, install heated oxygen sensor (HO2S). Refer to «HEATED OXYGEN SENSOR REPLACEMENT - POSITION 1»(ref-241686-S22936041462006081100000) in Engine Controls - 3.5L.
2. If removed, install EGR valve pipe. Refer to «EXHAUST GAS RECIRCULATION (EGR) PIPE REPLACEMENT»(ref-241686-S02817433772006081100000) in Engine Controls - 3.5L.
3. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-241684-S36257494482006081100000) in General Information.
4. Install the exhaust manifold gasket.
5. Install the exhaust manifold.
6. Install the exhaust manifold nuts. Tighten: Tighten the exhaust manifold nuts to 16 N.m (12 lb ft).
7. Install the exhaust manifold lower heat shield.
8. Install the exhaust manifold upper heat shield.
9. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
10. Install the catalytic converter. Refer to «Catalytic Converter Replacement»(ref-241745-S34308852242007022700000) .
11. Lower the vehicle.
12. Install the exhaust crossover pipe nuts/studs to the engine right side exhaust manifold. Refer to «Exhaust Crossover Pipe Replacement»(ref-241745-S33460791922007022700000) .
13. Install the exhaust crossover pipe heat shield.
14. Connect the HO2S electrical connector.
15. Install spark plug wires from the engine right bank spark plugs. Refer to «SPARK PLUG WIRE REPLACEMENT»(ref-241686-S08152444132006081100000) in Engine Controls - 3.5L.
16. Install ignition module and the ignition coils with the bracket. Refer to «IGNITION CONTROL MODULE REPLACEMENT»(ref-241686-S35343301302006081100000) in Engine Controls - 3.5L.
17. Install exhaust gas recirculation (EGR) valve. Refer to «EXHAUST GAS RECIRCULATION (EGR) VALVE REPLACEMENT»(ref-241686-S32798936942006081100000) in Engine Controls - 3.5L.
18. Install manifold air pressure (MAP) sensor. Refer to «MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT»(ref-241686-S05170885732006081100000) in Engine Controls - 3.5L.
19. Rotate the engine back to the original position. Refer to «ROTATING THE ENGINE FOR SERVICE ACCESS»(ref-241709-S15570154112006081100000) in Engine Mechanical - 3.5L.
20. Remove the throttle body air inlet duct. Refer to «AIR CLEANER INTAKE DUCT REPLACEMENT»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L.

Scheme 2

1. Remove the intake manifold cover, if necessary. Refer to «AIR CLEANER INLET DUCT REPLACEMENT»(ref-241687-S11604747922007030600000) .
2. Remove the generator. Refer to «GENERATOR REPLACEMENT (LZ9)»(ref-241706-S01681761022007022100000) .
3. Remove the ignition coil. Refer to «IGNITION COIL REPLACEMENT»(ref-241687-S11115013492007030600000) .
4. Disconnect the engine harness electrical connector (4) from the heated oxygen sensor (HO2S).
5. Remove the HO2S.
6. Disconnect the heater hose from the heater pipes.
7. Remove the nuts holding the heater pipes onto the throttle body.
8. Position the heater pipes out of the way.
9. Remove the exhaust crossover pipe heat shield bolts (1) and shield (2).
10. Remove the exhaust crossover pipe (2) to exhaust manifold nuts (1).
11. Remove the catalytic converter. Refer to «Catalytic Converter Replacement»(ref-241745-S34308852242007022700000) .
12. Remove the exhaust manifold heat shield bolts
13. Remove the exhaust manifold heat shield.
14. Remove the exhaust manifold bolts.
15. Remove the exhaust manifold.
16. Remove the exhaust manifold gasket.

1. Position a NEW exhaust manifold gasket to the cylinder head.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 20 N.m (15 lb ft).
4. Install the exhaust manifold heat shield
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
6. Install the catalytic converter. Refer to «Catalytic Converter Replacement»(ref-241745-S34308852242007022700000) .
7. Install the exhaust crossover pipe (2) to exhaust manifold nuts (1). Tighten: Tighten the exhaust manifold heat shield bolts to 20 N.m (15 lb ft).
8. Install the exhaust crossover pipe heat shield (2) and bolts (1). Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
9. Position the heater pipes back to the original position.
10. Install the nut holding the heater pipes onto the throttle body.
11. Connect the heater hoses to the heater pipes.
12. Install the HO2S. Tighten: Tighten the exhaust manifold heat shield bolts to 42 N.m (31 lb ft).
13. Connect the engine harness electrical connector (4) to the HO2S.
14. Install the ignition coil. Refer to «IGNITION COIL REPLACEMENT»(ref-241687-S11115013492007030600000) .
15. Install generator. Refer to «GENERATOR REPLACEMENT (LZ9)»(ref-241706-S01681761022007022100000) .
16. Install intake manifold cover, if necessary. Refer to «AIR CLEANER INLET DUCT REPLACEMENT»(ref-241687-S11604747922007030600000) .

1. Disconnect the battery ground (negative) cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) in Engine Electrical.
2. Remove the throttle body air inlet duct.
3. Drain the coolant from the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) in Engine Cooling.
4. Disconnect the inlet radiator hose from the engine. Refer to «RADIATOR HOSE REPLACEMENT - INLET»(ref-241700-S17953640892006081100000) in Engine Cooling.
5. Remove the thermostat bypass pipe. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT - LX9 (3.5L)»(ref-241700-S05879389552007022300000) in Engine Cooling.
6. Remove the exhaust crossover heat shield bolts.
7. Remove the exhaust crossover heat shield.
8. Remove the exhaust crossover pipe studs/nuts.
9. Remove the exhaust crossover pipe.

1. Install the exhaust crossover pipe.
2. Install the exhaust crossover pipe studs/nuts. Tighten: Tighten the exhaust crossover pipe studs/nuts to 25 N.m (18 lb ft).
3. Install the exhaust crossover heat shield.
4. Install the exhaust crossover heat shield bolts. Tighten: Tighten the exhaust crossover heat shield bolts to 10 N.m (89 lb in).
5. Install the thermostat bypass pipe. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT - LX9 (3.5L)»(ref-241700-S05879389552007022300000) in Engine Cooling.
6. Install inlet radiator hose from the engine. Refer to «RADIATOR HOSE REPLACEMENT - INLET»(ref-241700-S17953640892006081100000) in Engine Cooling.
7. Fill coolant from the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM (STATIC FILL)»(ref-241700-S12524063102006081100000) in Engine Cooling.
8. Install the throttle body air inlet duct.
9. Connect the battery ground (negative) cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE»(ref-241706-S19444827352007022100000) in Engine Electrical.

1. Remove the air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .
2. Disconnect the heater hoses from the heater pipes.
3. Remove the nuts holding the heater pipes onto the throttle body.
4. Position the heater pipes out of the way.
5. Remove the exhaust crossover heat shield bolts (1).
6. Remove the exhaust crossover heat shield (2).
7. Remove the exhaust crossover pipe nuts (1).
8. Remove the exhaust crossover pipe (2).
9. Remove the exhaust crossover pipe seals.

1. Install the exhaust crossover pipe seals to the exhaust manifolds.
2. Install the exhaust crossover pipe (2).
3. Install the exhaust crossover pipe nuts (1). Tighten: Tighten the exhaust manifold heat shield bolts to 20 N.m (15 lb ft).
4. Install the exhaust crossover heat shield (2).
5. Install the exhaust crossover heat shield bolts (1). Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
6. Position the heater pipes back to the original position.
7. Install the nuts holding the heater pipes on the throttle body.
8. Connect the heater hoses onto the heater pipes.
9. Install air cleaner outlet duct. Refer to «AIR CLEANER OUTLET DUCT REPLACEMENT»(ref-241687-S20617288222007030600000) .

1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the right exhaust manifold pipe stud nuts from the exhaust manifold studs.
3. In order to remove the exhaust seal disconnect any hangers necessary to reposition the exhaust system.
4. Reposition the exhaust system.
5. Remove the exhaust manifold pipe gasket.

1. Install the exhaust manifold pipe gasket.
2. Return the exhaust system to the proper position.
3. Connect any hangers.
4. Remove the exhaust system support.
5. Install the right exhaust manifold pipe stud nuts to the exhaust manifold pipe studs. Tighten: Tighten the right exhaust manifold pipe stud nuts to 35 N.m (26 lb ft).
6. Inspect the exhaust system for leaks and underbody contact.
7. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-241684-S36257494482006081100000) in General Information.
2. Disconnect the heated oxygen sensor connector.
3. Remove the exhaust manifold pipe nuts from the exhaust manifold pipe studs.
4. Remove the catalytic converter nuts from the exhaust pipe.
5. Remove the 3-way catalytic converter.

1. Install a new catalytic converter gasket.
2. Install a new exhaust manifold pipe gasket.
3. Position and support the new 3-way catalytic converter under the vehicle.
4. Install the exhaust pipe to the 3-way catalytic converter with the catalytic converter nuts. Do not tighten the nuts.
5. Install the exhaust manifold pipe nuts to the exhaust manifold pipe studs. Tighten: Tighten the exhaust manifold pipe nuts to the exhaust manifold pipe stud to 35 N.m (26 lb ft). Tighten the catalytic converter nuts to 34 N.m (25 lb ft).
6. Connect the heated oxygen sensor connector.
7. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the exhaust insulators (1) from the exhaust system (2) and vehicle body if replacement of insulator is necessary.
3. Remove the exhaust system hanger bolts (2).
4. Remove the exhaust system hanger (1).

1. Install the exhaust system hanger (1).
2. Install the exhaust system hanger bolts (2). Tighten: Tighten the bolts to 35 N.m (26 lb ft).
3. Install any exhaust insulators (1) to the exhaust system (2) and vehicle body if replacement of insulator was necessary.
4. Lower the vehicle.

The muffler is serviced as one piece from the catalytic converter to the tail pipe.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Use a utility stand in order to support the catalytic converter.
3. Remove the catalytic converter bolts.
4. Remove the catalytic converter gasket.
5. Remove the exhaust hanger insulators from the exhaust pipes.
6. Support and lower the rear crossmember. AWD models refer to «Crossmember Replacement»(ref-241708-S34145197702006081100000) in Frame and Underbody.
7. Remove the muffler and exhaust pipes towards the front of the vehicle and over the rear axle.
8. Clean the catalytic converter flange and the muffler flange.

1. Install the muffler and exhaust pipes over the rear axle and towards the rear of the vehicle.
2. Install the exhaust hanger insulators to the exhaust pipes.
3. Install rear crossover. AWD models refer to «Crossmember Replacement»(ref-241708-S34145197702006081100000) in Frame and Underbody.
4. Install a new catalytic converter gasket.
5. Install the catalytic converter bolts. Tighten: Tighten the catalytic converter bolts to 34 N.m (25 lb ft).
6. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the catalytic converter. Refer to «Catalytic Converter Replacement»(ref-241745-S34308852242007022700000) .
3. Use a drill to remove the catalytic converter heat shield rivets.
4. Remove the catalytic converter heat shield.

1. Install the catalytic converter heat shield.
2. Install the catalytic converter heat shield to the vehicle with new rivets.
3. Install the catalytic converter. Refer to «Catalytic Converter Replacement»(ref-241745-S34308852242007022700000) .
4. Lower the vehicle.

1. Remove the muffler. Refer to «Muffler Replacement»(ref-241745-S05335169912006081100000) .
2. Drill out the resonator heat shield rivets (1).
3. Remove the heat shield.

1. Position the heat shield to the underbody.
2. Install NEW rivets (1) attaching the resonator heat shield to the underbody.
3. Install muffler. Refer to «Muffler Replacement»(ref-241745-S05335169912006081100000) .

1. Remove the muffler. Refer to «Muffler Replacement»(ref-241745-S05335169912006081100000) .
2. Drill out the muffler heat shield rivets
3. Drill out the muffler heat shield rivets, if equipped with a long wheel base (LWB).
4. Remove the muffler heat shield.

1. Install the muffler heat shield.
2. Position the heat shield to the underbody, if equipped with a LWB.
3. Install NEW rivets attaching the muffler heat shield to the underbody.
4. Position the heat shield to the underbody.
5. Install NEW rivets attaching the muffler heat shield to the underbody.
6. Install muffler. Refer to «Muffler Replacement»(ref-241745-S05335169912006081100000) .