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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 COMPANY
  6. Attach the intermediate exhaust assembly (2) by installing the center insulator hanger bracket to differential retaining bolt (1).
    7. Fig 2: Identifying Front Insulator Hangers
    GM1947040Courtesy of GENERAL MOTORS COMPANY
  7. Attach the intermediate exhaust assembly (2) by installing the front insulator hangers (1) if fitted.
    8. CAUTION:

    Refer to Fastener Caution .

  8. Tighten the intermediate exhaust assembly to rear muffler retaining bolts.

    Tighten 

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

    9. Fig 3: Identifying Intermediate Exhaust Assembly To Catalytic Converter Retaining Nuts
    GM1947044Courtesy of GENERAL MOTORS COMPANY
  9. Align the intermediate exhaust assembly (2) to the right catalytic converter (1).
  10. Tighten the intermediate exhaust assembly to right catalytic converter retaining nuts (3).

    Tighten 

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

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

    Tighten 

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

    13. Fig 5: Identifying Oxygen Sensor & Wiring Harness Connector
    GM1949877Courtesy of GENERAL MOTORS COMPANY
  13. Connect the right post-catalytic converter HO2S electrical connector (1).
    14. Fig 6: Identifying HO2S Electrical Connector
    GM1949882Courtesy of GENERAL MOTORS COMPANY
  14. Connect the left post-catalytic converter HO2S electrical connector (1).
    15. Fig 7: Identifying Intermediate Exhaust Assembly To Rear Muffler Retaining Bolts
    GM1947045Courtesy of GENERAL MOTORS COMPANY
  15. Connect the left rear muffler (1) to the intermediate exhaust assembly (2).
  16. Install the left rear muffler to intermediate exhaust assembly retaining bolts (3).

    Tighten 

    Tighten the bolts 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. Refer to Exhaust System Alignment .
  18. Lower the vehicle to the ground.
  19. Connect the battery ground cable to the battery. Refer to Battery Negative Cable Disconnection and Connection .
  20. If re-programming is required. Refer to Control Module References .
  21. Perform diagnostic system check using diagnostic scan tool, clear all relative DTCs and inspect the system for correct operation.
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