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Installation Procedure

  1. Install the left pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 .
    2. Fig 1: Identifying Left Catalytic Converter To Exhaust Manifold Retaining Nuts
    GM1949706Courtesy of GENERAL MOTORS CORP.
    NOTE:

    Make sure that a NEW sealing ring is fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.

  2. From underneath the vehicle, position the left catalytic converter (2) to the exhaust manifold (3).
    3. NOTE:

    Do not fully tighten the left catalytic converter to exhaust manifold retaining nuts (1) at this stage.

  3. Install the NEW left catalytic converter to exhaust manifold retaining nuts (1).

    Do not fully tighten at this stage.

  4. Install the right pre-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 .
    5. Fig 2: Identifying Right Catalytic Converter To Exhaust Manifold Retaining Nuts
    GM1949711Courtesy of GENERAL MOTORS CORP.
    NOTE:

    Make sure that a NEW sealing ring is fitted prior to installation. Failure to comply may cause the exhaust system to perform poorly.

  5. From underneath the vehicle, position the right catalytic converter (2) to the exhaust manifold (1).
    6. NOTE:

    Do not fully tighten the right catalytic converter to exhaust manifold retaining nuts (3) at this stage.

  6. Install the NEW right catalytic converter to exhaust manifold retaining nuts (3).

    Do not fully tighten at this stage.

  7. Lower the vehicle.
    8. Fig 3: Left Catalytic Converter To Exhaust Manifold Retaining Nuts
    GM1949713Courtesy of GENERAL MOTORS CORP.
    CAUTION:

    Refer to Fastener Caution .

  8. Tighten the left catalytic converter to exhaust manifold retaining nuts (1) to 45 N.m (33 lb ft).
    9. Fig 4: Identifying Right Catalytic Converter To Exhaust Manifold Retaining Nuts
    GM1949714Courtesy of GENERAL MOTORS CORP.
  9. Tighten the right catalytic converter to exhaust manifold retaining nuts (1) to 45 N.m (33 lb ft).
    10. WARNING:

    To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

  10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  11. Install the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 .
  12. Install the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 .
  13. With the aid of an assistant, or using a suitable jack; position the exhaust crossover pipe assembly to the vehicle.
    14. Fig 5: Identifying Center Insulator Hanger Bracket To Differential Retaining Bolts
    GM1947047Courtesy of GENERAL MOTORS CORP.
  14. Align the exhaust system to the center insulator hanger bracket to differential retaining stud (1).
    15. Fig 6: Exhaust System And Insulator Hangers
    GM2543500Courtesy of GENERAL MOTORS CORP.
  15. Align the exhaust system (2) to the front hanger studs and install the front insulator hangers (1).
  16. Remove the jack supporting the exhaust system.
    17. Fig 7: Identifying Intermediate Exhaust Assembly To Catalytic Converter Retaining Nuts
    GM1947044Courtesy of GENERAL MOTORS CORP.
  17. Align the exhaust crossover pipe exhaust assembly (2) to the right catalytic converter (1).
  18. Install the intermediate exhaust assembly to right catalytic converter retaining nuts (3) and tighten to 40 N.m (30 lb ft).
    19. Fig 8: Identifying Intermediate Exhaust Assembly To Left Catalytic Converter Retaining Nuts
    GM1947042Courtesy of GENERAL MOTORS CORP.
  19. Align the exhaust crossover pipe exhaust assembly (2) to the left catalytic converter (1).
  20. Install the intermediate exhaust assembly to left catalytic converter retaining nuts (3) and tighten to 40 N.m (30 lb ft).
    21. Fig 9: Identifying Center Insulator Hanger Bracket To Differential Retaining Bolts
    GM1947047Courtesy of GENERAL MOTORS CORP.
  21. Install the center insulator hanger bracket to differential retaining nut (1) and tighten to 45 N.m (33 lb ft).
    22. Fig 10: Identifying HO2S Electrical Connector
    GM1949882Courtesy of GENERAL MOTORS CORP.
  22. Connect the left post-catalytic converter HO2S electrical connector (1).
    23. Fig 11: Identifying Oxygen Sensor & Wiring Harness Connector
    GM1949877Courtesy of GENERAL MOTORS CORP.
  23. Connect the right post-catalytic converter HO2S electrical connector (1).
    24. Fig 12: Identifying Left Pre-Catalytic Converter Heated Oxygen Sensor (HO2S) Electrical Connector
    GM1950735Courtesy of GENERAL MOTORS CORP.
  24. Connect the left pre-catalytic converter HO2S electrical connector (1).
    25. Fig 13: Identifying Right Pre-Catalytic Converter Heated Oxygen Sensor (HO2S) Electrical Connector
    GM1950736Courtesy of GENERAL MOTORS CORP.
  25. Connect the right pre-catalytic converter HO2S electrical connector (2).
    26. Fig 14: Transmission Tunnel Cross-Brace To Body Retaining Bolts
    GM1949712Courtesy of GENERAL MOTORS CORP.
  26. Install the transmission tunnel cross-brace (1).
  27. Install the transmission tunnel cross-brace to body retaining bolts (2) and tighten to 58 N.m (43 lb ft).
    28. Fig 15: View Of Right Rear Muffler
    GM1949730Courtesy of GENERAL MOTORS CORP.
  28. Install the right rear muffler (1) to the vehicle.
    29. Fig 16: Identifying Right Rear Muffler To Intermediate Exhaust Assembly Retaining Bolts
    GM1949729Courtesy of GENERAL MOTORS CORP.
  29. Connect the right rear muffler (1) to the exhaust crossover pipe assembly (2).
  30. Install the right rear muffler to exhaust crossover pipe assembly retaining bolts (2) and tighten to 45 N.m (33 lb ft).
    31. Fig 17: View Of Left Rear Muffler
    GM1949728Courtesy of GENERAL MOTORS CORP.
  31. Install the left rear muffler (1) to the vehicle.
    32. Fig 18: Identifying Intermediate Exhaust Assembly To Rear Muffler Retaining Bolts
    GM1947045Courtesy of GENERAL MOTORS CORP.
  32. Connect the left rear muffler (1) to the exhaust crossover pipe assembly (2).
  33. Install the left rear muffler to exhaust crossover assembly retaining bolts (3) and tighten to 45 N.m (33 lb ft).
    34. Fig 19: Left Rear Insulator Hanger And Body Retaining Bolts
    GM2543504Courtesy of GENERAL MOTORS CORP.
  34. Install the left rear insulator hanger to body retaining bolts (1) and tighten to 26 N.m (19 lb ft).
    35. Fig 20: Right Rear Insulator Hanger And Body Retaining Bolts
    GM2543503Courtesy of GENERAL MOTORS CORP.
  35. Install the right rear insulator hanger to body retaining bolts (1) and tighten to 26 N.m (19 lb ft).
  36. 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.
  37. Lower the vehicle.
  38. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) , Battery Negative Cable Disconnection and Connection (Auxiliary) .
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