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Home >> Chevrolet >> 2011 >> Caprice >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Exhaust Crossover Pipe Replacement >> Installation Procedure
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Installation Procedure

  1. Clean all threads and flange faces of the intermediate exhaust system.
  2. Always check the condition of the catalytic converter to intermediate pipe flange gaskets and replace as necessary.
  3. Install the left post-catalytic converter HO2S to the intermediate exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 .
  4. Install the right post-catalytic converter HO2S to the intermediate exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 .
    5. WARNING:

    Refer to Exhaust Service Warning .

    CAUTION:

    Refer to Exhaust System Inspection Caution .

  5. Position the intermediate exhaust assembly to the vehicle using a suitable jack.
    6. Fig 1: Identifying Center Insulator Hanger Bracket To Differential Retaining Bolts
    GM1947047Courtesy of GENERAL MOTORS CORP.
  6. Attach the intermediate exhaust assembly by installing the center insulator hanger bracket to differential stud (1).
    7. CAUTION:

    Refer to Fastener Caution .

  7. Install the insulator hanger bracket to differential retaining nut (1) and tighten to

    Tighten 

    Tighten the nuts to 40 N.m (30 lb ft).

    8. Fig 2: Identifying Front Insulator Hangers
    GM1947040Courtesy of GENERAL MOTORS CORP.
  8. Attach the intermediate exhaust assembly (2) by installing the front insulator hangers (1) if fitted.
  9. Tighten the intermediate exhaust assembly to rear muffler retaining bolts.
    10. Fig 3: Identifying Intermediate Exhaust Assembly To Catalytic Converter Retaining Nuts
    GM1947044Courtesy of GENERAL MOTORS CORP.
  10. Align the intermediate exhaust assembly (2) to the right catalytic converter (1).
  11. Tighten the intermediate exhaust assembly to right catalytic converter retaining nuts (3).

    Tighten 

    Tighten the nuts to 40 N.m (30 lb ft).

    12. Fig 4: Identifying Intermediate Exhaust Assembly To Left Catalytic Converter Retaining Nuts
    GM1947042Courtesy of GENERAL MOTORS CORP.
  12. Align the intermediate exhaust assembly (2) to the left catalytic converter (1).
  13. Tighten the intermediate exhaust assembly to left catalytic converter retaining nuts (3).

    Tighten 

    Tighten the nuts to 40 N.m (30 lb ft).

    14. Fig 5: Identifying Oxygen Sensor & Wiring Harness Connector
    GM1949877Courtesy of GENERAL MOTORS CORP.
  14. Connect the right post-catalytic converter HO2S electrical connector (1).
    15. Fig 6: Identifying HO2S Electrical Connector
    GM1949882Courtesy of GENERAL MOTORS CORP.
  15. Connect the left post-catalytic converter HO2S electrical connector (1).
    16. Fig 7: Rear Muffler Retaining Bolts
    GM2565167Courtesy of GENERAL MOTORS CORP.
  16. Connect the left rear muffler (3) to the intermediate exhaust assembly (2).

    Tighten 

    Tighten the bolts (1) to 45 N.m (33 lb ft).

  17. Make sure that the exhaust system is clear of all other components and chassis. If the exhaust system is not clear of all the other components loosen all retaining nuts and re-align.
  18. Lower the vehicle to the ground.
  19. If re-programming is required. Refer to Control Module References .
  20. Perform diagnostic system check using diagnostic scan tool, clear all relative DTCs and inspect the system for correct operation.
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