Turbocharger

Specifications
F asten er Tig h ten in g S p ecificatio n s
Specification
Application Metric English
Actuator Bracket Bolts Air Cleaner Mounting Bracket Bolt/Nut 23 N-m 17 lb ft
Air Cleaner Large Bolt 30 N-m 22 lb ft
Air Cleaner Smaller Bolt 5 N-m 45 lb in
Exhaust Clamp 8 N-m 71 lb in
Extension (Air Intake) Bolts 23 N-m 17 lb ft
Heat Shield Bolts 6 N-m 56 lb in
Oil Drain Tube (Return) Flange Bolts 26 N-m 19 lb ft
Oil Feed Line 17 N-m 13 lb ft
Rubber Hose Connector Clamps 6 N-m 55 lb in
Rubber Inlet Elbow Clamps 2 N-m 18 lb in
Turbocharger Brace (Long) Bolt 50 N-m 37 lb ft
Turbocharger Brace (Long) Nut 34 N-m 26 lb ft
Turbocharger Brace (Short) Bolt 25 N-m 19 lb ft
Turbocharger to Exhaust Manifold Nuts 58 N-m 43 lb ft
Upper Intake Manifold Cover Bolts 11 N-m 90 lb in

Diagnostic information and Procedures

Lacks Pow er, No B lack S m o ke at W O T
Problem Action
Insufficient fuel supply to the Refer to Fuel Supply System Check in Engine Controls.
injection pump

Lacks P ow er, B lack S m oke at W O T

Problem
Restricted air filter
Obstructed air intake duct to the
turbocharger compressor wheel
Air leak in the compressor wheel
inlet/outlet duct
No vacuum signal to the wastegate
actuator
Ruptured wastegate actuator
diaphragm
Air leak between the intake manifold
and the engine
Exhaust gas leak between the
cylinder head exhaust ports and the
turbine inlet
Damaged turbocharger
Fuel system problem
Action
Replace the air filter.
Remove the obstruction(s).
Inspect the inlet/outlet ducts for loose connections. Tighten the connections and /or
replace damaged duct work.
Check for DTCs. Refer to DTC List (Definitions) in Engine Controls.
Refer to Wastegate Actuator.
Refer to Exhaust Manifold Removal (Left Side) or Exhaust Manifold Removal (Right
Side) in Engine Mechanical.
Repair the leaks.
Find the cause of damage. Refer to Turbocharger. Correct the cause of damage.
Replace the turbocharger if necessary.
Refer to Fuel System Diagnosis (System Check) in Engine Controls.

Problem
Restriction and /or air leak in the
compressor inlet ducting and/or outlet
ducting
Rotating components or turbocharger
out of balance
Compressor and/or turbine wheel
contacting the housing.
Tu rb o ch arg er N oise
Action
Inspect the compressor inlet/outlet ducting. Remove any restrictions. Tighten the
connections and/or replace any damaged duct work.
Replace the turbocharger. Refer to Turbocharger.
Refer to Turbocharger. Locate the reason for damage. Replace the turbocharger.

Blue E xhaust S m oke, W arm Engine O nly

Problem
Lack of intake air
Restricted oil drain tube
Oil leakage past the turbo seals.
Refer to Inspection.
Action
Refer to DTC P1191 Intake Air Duct Leak in Engine Controls.
Clean or replace the oil drain tube. Refer to Oil Pressure High or Low in Engine
Controls.
Replace the turbocharger. Refer to Turbocharger.

T u rb o c h a r g e r
Turbochargers are extremely reliable units. The
majority of inoperative turbochargers are caused by
the following conditions:
• Dirt in the oil
• Oil lag (lack of oil flow)
• Foreign objects or debris entering the turbocharger
• Plugged or restricted air cleaner systems
Problems that are frequently blamed on the
turbocharger may be caused by other engine
components. Such problems may include the following
conditions:
• Lack of power
• Black smoke
• Blue smoke (excess oil consumption)
• Engine performance problems
Completely inspect the turbocharger and all other
engine components that may cause similar conditions
before replacing the turbocharger. Refer to Lacks
Power, No Black Smoke at WOT or Lacks Power,
Black Smoke at WOT or Turbocharger Noise
Use the following information to diagnose problems
caused by the turbocharger.
If you cannot make a diagnosis from the following
information, refer to the tables listed
immediately below:
• Lacks Power, No Black Smoke at WOT
• Lacks Power, Black Smoke at WOT
• Turbocharger Noise
• Blue Exhaust Smoke, Warm Engine Only
If you determine that the turbocharger is the cause of
the problem, the turbocharger must be replaced as
a complete unit. THE TURBOCHARGER IS
SERVICED AS A COMPLETE UNIT. THE
WASTEGATE ACTUATOR MAY BE SERVICED
SEPARATELY.
Check for the following noises:

Problem
High-pitched whine
Cycling up and down in pitch
Sharp, high-pitched scream
T u rb o ch arg er
Action
Check for an exhaust leak or a leak in the air induction system.
Check for the following conditions:
• A blockage in the air inlet duct
• A restricted air cleaner
• A build up of dirt on the compressor wheel of the turbocharger (oil film is
normal)
Check the bearings. The bearings may have deteriorated and one (or both) of the
wheels may be rubbing on its housing (this results in blue exhaust smoke).
N orm al C om pressor W heel D am age by a Hard O b ject

D am age by a Soft O bject C o m pressor Blades S how H eavy R ubbing

Ensure that the following conditions do not exist on

the compressor wheel blades:
• Cracks
• Bends
• Erosion of the blades
• Broken blades
Check the housing for signs of rubbing. W a s te g a te A c tu a to r
Check the compressor wheel for a build-up of dirt. Tools Required
C a u tio n : D o n o t f e e l a n y c o m p o n e n t s o f th e J 23738-A Hand Operated Vacuum Pump
t u r b o c h a r g e r w h ile th e e n g in e is r u n n in g . M a k e
s u r e t h a t th e tu r b o c h a r g e r h a s s t o p p e d r o ta tin g
a n d th e tu r b o c h a r g e r a n d e n g in e h a v e c o o le d
d o w n b e fo r e h a n d lin g . R o ta tin g p a r t s a n d e x tr e m e
h e a t m a y c a u s e s e r io u s p e r s o n a l in ju r y if
h a n d le d .

Important:
• The inside of the air intake duct (rubber inlet
elbow), turbocharger compressor wheel and
housing can be quite oily due to the venting of the
crankcase vapors into the intake system. The
oily condition is considered normal with this engine
application.
• The crankcase depression regulator (CDR) valve
does not prevent oil vapors from entering the
turbocharger compressor inlet system.
• Carefully grasp the compressor wheel nut with
your fingers and rotate the wheel in a clockwise
direction. The wheel should turn freely with
no signs of binding or scraping (housing contact). The wastegate actuator assembly can be replaced
separately from the turbocharger assembly. Use
• Rotate the turbocharger while pushing in and the following procedure to check the operation of the
pulling out on the compressor wheel; the wastegate actuator:
wheel should rotate freely with no contact with the
1. Turn the engine off.
housing.
2. Inspect the actuator rod and lever. The actuator
• Carefully grasp the compressor wheel nut with rod and lever should move back and forth without
your fingers and rotate the wheel while moving any tension.
the wheel up and down (radially). There should be Apply 5 inches HG vacuum to the actuator. The
no compressor wheel to the housing contact. actuator rod and lever should close the wastegate.
NOTE: AXIAL AND RADIAL PLAY IS NORMAL
3. Look for the rod to move toward the front of
EVEN ON A NEW TURBOCHARGER. If the
the engine.
compressor wheel comes in contact with
the housing, it will be very evident when rotating
the wheel. The wheel will drag or scrape on
the housing surface and visual damage will be
evident on the wheel blades and the housing
surface.
• If the turbocharger does not pass any of these
inspections, replace the turbocharger. Refer to
Turbocharger.

177090

With the engine running, the actuator rod should snap

back to a closed position. If not, the wastegate actuator
is defective and should be replaced. For removal of the
wastegate actuator, refer to Wastegate Actuator.
 Repair Instructio ns
T u rb o c h a rg e r

R em oval Procedure
1. Open the hood.
C a u t io n : R e f e r t o B a t t e r y D is c o n n e c t C a u t io n in
C a u tio n s a n d N o tic e s .
2. Disconnect the negative battery cable.
3. Remove the upper intake manifold cover.
4. Remove the crankcase depression regulator
(CDR) valve and tube from the air cleaner.
Refer to CDR Valve and Hoses Replacement in
Engine Controls.
Important: Some quantity of oil will exist inside the
vent system. The crankcase vapor consists of
vaporized oil that condenses within the vent and
intake system. The inside of the air duct and
compressor wheel housing will have some oil due to
the venting of the crankcase vapors.
5. Loosen the clamps on the connector between the
upper intake manifold and the turbocharger.
Important: Silicone sealant is used between the
connector hose, the upper intake manifold, and the
turbocharger.
6. Remove the air cleaner extension and air cleaner
assembly from the turbocharger:
6.1. Break the seal between the connector
hose, turbocharger compressor inlet, and
the upper intake manifold by using a thin flat
screwdriver.
6.2. Slide the connector hose over the upper
intake manifold.
7. Remove the braces from the turbocharger.
8. Remove the vacuum line from the wastegate
actuator.

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 9. Remove the oil feed line from the turbocharger.
Important: Removing the right front wheel and the
inner splash shield will aid in removing and installing
the attaching bolts for the turbocharger and for the
oil drain tube.
10. Remove the right front wheel and inner splash
shield. Refer to Wheel Removal (Single Wheels)
in Tires and Wheels.

11. Remove the oil drain tube and nuts.

12. Remove the exhaust pipe clamp from the

turbocharger outlet.
 13. Remove the turbocharger assembly.

177099

Installation P rocedure
Important: Perform the following steps before the
turbocharger Is installed:
1. Check the intake and exhaust systems leading to
and from the turbocharger to make sure that there
is no foreign material that may cause damage
to the turbocharger during all levels of operation.
At the same time, check the mating surface of
the exhaust manifold for cracks and replace
as necessary.
2. Make sure that the turbocharger and the exhaust
manifold flanges are clean and free of any foreign
material. Use a high temperature anti-seize
compound, GM P/N 1052771, on all threaded
fasteners that are connected to the turbocharger.
1. Install the studs to the turbocharger.
2. Install the turbocharger to the exhaust manifold.
N o t i c e : Refer to Fastener Notice in Cautions and
Notices.
3. Install the studs and nuts.
Tighten
Tighten the studs and nuts to 58 N-m (43 lb ft).
 4. Install the oil drain tube and gasket.
5. Install the mounting bolts.
Tighten
Tighten the bolts to 26 N-m (19 lb ft).
6. Install the right front inner splash shield.
7. Install the right front wheel. Refer to Wheel
Installation (Single Wheels-Front or Rear) in Tires
and Wheels.

177097

Important: Fill the oil feed hole at the top of the

turbocharger with a small amount of clean engine oil
(1 to 2 cc) while turning the compressor wheel by hand
to lubricate the bearings in the turbocharger.

8. Install the oil feed line to the turbocharger.

9. Tighten the oil feed line fitting.
Tighten
Tighten the fitting to 17 N-m (13 lb ft).

10. Install the exhaust pipe to the turbocharger.

11. Tighten the exhaust clamp.
Tighten
Tighten the clamp to 8 N-m (71 lb in).
 Important: Apply a small amount of silicone sea lant,
GM P/N 9985943 or the equivalent, to a clean
turbocharger compressor inlet (not the upper intake
manifold) before installing the connector hose to
prevent oil leakage from the closed breather system.
12. Install the connector hose (with clamps) to
the upper intake manifold:
12.1. Slide the connector hose over the upper
intake manifold.
12.2. Slide the connector hose forward onto the
turbocharger compressor inlet.
12.3. Center the connector hose and tighten the
clamps.
Tighten
Tighten the clamps to 6 N-m (50 lb in).
13. Install the long and short braces to the
turbocharger.
14. Install the mounting bolt for the long brace.
Tighten
Tighten the bolt (long brace) to 50 N-m (37 lb ft).
15. Install the mounting nut for the long brace.
Tighten
Tighten the nut (Long brace) to 40 N-m (30 lb ft).
16. Install the mounting bolts for the short brace.
Tighten
Tighten the bolts (short brace) to 25 N-m (19 lb ft).
17. Install the vacuum line to the wastegate actuator.
18. Install the air cleaner extension and air cleaner
assembly.
19. Install the CDR valve and hose. Refer to CDR
Valve and Hoses Replacement in Engine
Controls.

20. Install the upper intake manifold cover.

21. Install the upper intake manifold cover bolts.
Tighten
Tighten the bolts to 11 N-m (90 lb in).
22. Install the negative battery cable.
23. Run the engine at idle for at least 2 minutes after
completing the installation of the turbocharger.
While running the engine, check for any oil leaks
at the oil supply and return hoses.

174662
W a s te g a te A c tu a to r

R em oval P rocedure
1. Open the hood.
C a u t io n : R e f e r t o B a t t e r y D is c o n n e c t C a u t io n in
C a u tio n s a n d N o tic e s .
2. Disconnect the negative battery cable.
3. Remove the upper intake manifold cover.
4. Remove the vacuum hose.
5. Remove the E-clip retainer from the wastegate
lever pin.

6. Remove the wastegate mounting bolts from the

turbocharger.

7. Remove the wastegate assembly from the

turbocharger.

177446
 Installation P rocedure
1. Install the wastegate to the turbocharger.

177446

N o t i c e : Refer to Fastener Notice in Cautions and

Notices.

2. Install the wastegate mounting bolts to the

turbocharger.
Tighten
Tighten the bolts to 23 N-m (17 lb ft).
3. Install the E-clip to the wastegate lever pin.
4. Install the vacuum hose.

177419

5. Install the upper intake manifold cover.

6. Connect the negative battery cable.

174662
Descriptio n and Operation
T u rb o c h a rg e r
The turbocharger is used to increase the amount of air
that enters the engine’s cylinders. The increase of
air allows a proportional increase of fuel that is injected
into the cylinders. The results are:
• Increased power output
• More complete combustion of the fuel
• Cooling of the cylinder heads, the pistons, the
valves, and the exhaust gas. This cooling
effect helps extend engine life.
Heat energy and pressures in the engine exhaust gas
drives the turbine wheel. Exhaust gas is directed to
the turbine housing. The turbine housing acts as
a nozzle to direct the exhaust gas flow to the turbine
wheel blades, which drive the shaft wheel assembly.
The compressor wheel is attached directly to the shaft
and rotates at the same speed as the turbine wheel.
Clean air from the air cleaner and crankcase vapors
are drawn into the compressor housing and wheel,
where the air is compressed and delivered through a
crossover pipe to the engine air intake manifold,
then into the cylinders. The inside of the turbocharger
compressor housing, the compressor wheel, and
the inside of the intake manifold can be quite oily due
to the ingestion of the crankcase vapors. A wastegate
valve in the exhaust housing regulates the amount
of air pressure rise and the air volume delivered to the
engine from the compressor outlet.
The PCM monitors turbo boost pressure and controls
the position of the wastegate valve. More vacuum
is applied to the actuator to close the wastegate
if increased boost is needed. The vacuum applied to
the actuator is reduced if less turbo boost is needed. A
reduction of vacuum allows the wastegate valve to
open, resulting in additional exhaust bypassing the
turbine wheel.
For more information about the vacuum operated
wastegate controlled by the PCM, refer to Wastegate
Actuator.
Specificatio ns
F asten er T ightening S p ecificatio n s
Specification
Application Metric English
Fan Clutch Retaining Nuts 30 N-m 22 lb ft
Upper and Lower Fan Shroud Bolt/Screw 5 N*m 44 lb in
Vacuum Pump to the Generator Bracket Mounting Bolts 25 N-m 18 lb ft

V acuum S p ecificatio n s
Vacuum
Elevation Metric English
Sea Level -70 kPa 21 in
152 m (5,000 ft) -60 kPa 18 in
3048 m (10,000 ft) -49 kPa 14 in
4572 m (15,000 ft) -40 kPa 12 in

GM SPO G roup N um bers

Application GM SPO Group Number
Bolt 08.900
Clamp 88.888
Emission Vacuum Control Harness (L56) 03.675
Emission Vacuum Control Harness (L85) 03.675
Hose 08.962
Vacuum Pump Pulley 03.280
Vacuum Pump Hose 03.280
Vacuum Pump 03.280

Diagnostic Information and Procedures

V a c u u m P u m p D ia g n o s is

No V acuum
Problem Action
N o t ic e : Test should be taken with the engine running. Vacuum should reach —70 kPa (21 in Hg) minimum at sea level
within 30 seconds. Elevation (feet/meters above sea level) will affect the vacuum reading you will see on the vacuum gauge.
Broken drive belt Replace the drive belt.
Defective belt tensioner (if equipped) Replace the belt tensioner.
Pulley for the vacuum pump is loose Replace the pulley.
Broken vacuum line Locate and repair the break in the vacuum line.

Low V acuum or Fluctuating V acuum G auge

Problem Action
N o t ic e : Test should be taken with the engine running. Vacuum should reach —70 kPa (21 in Hg) minimum at sea level
within 30 seconds. Elevation (feet/meters above sea level) will affect the vacuum reading you will see on the vacuum gauge.
Wrong drive belt Replace the drive belt.
Defective belt tensioner (if equipped) Replace the defective belt tensioner (if equipped).
Pulley loose on vacuum pump shaft Replace the vacuum pump pulley.
Defective vacuum pump Replace the vacuum pump. Refer to Vacuum Pump Replacement
Defective accessories Locate and repair or replace the defective accessory(s).
Repair Instructions
V a c u u m P u m p R e p la c e m e n t

R em oval P rocedure
Tools Required
• J 25034-B Pump Pulley Remover
• J 25033-BP ump Pulley Installer
1. Remove the drive belt from the drive pulleys.
Refer to Drive Belt Replacement
(6.5L Drive Belt).
2. Remove the vacuum line from the vacuum pump.

3. Remove the vacuum pump mounting bolts.

4. Remove the vacuum pump from the accessory
bracket.
 5, Remove the vacuum pump pulley:
5.1. Place the vacuum pump in a vise.
5.2. Attach the J 25034-B to the pulley.
5.3. Remove the pulley from the vacuum pump
using the J 25034-B.

6. Install the vacuum pump pulley on the

vacuum pump.
6.1. Attach the J 25033-B to the vacuum pump
pulley.
6.2. Install the vacuum pump pulley to the
vacuum pump.
6.3. Remove the J 25033-B.
7. Remove the vacuum from the vise.

Installatio n P rocedure
1. Install the vacuum pump.
N otice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the mounting bolts.
Tighten
Tighten the bolts to 25 N-m (18 lb ft).

177149
 3. Install the vacuum line to the vacuum pump.
4. Install the drive belt on the drive pulleys. Refer to
Drive B elt R eplacem ent (6.5L D rive Belt).

Description and Operation

G e n e ra l D e s c rip tio n
The vacuum pump is mounted on the right, lower side
of the 6.5L diesel engine and is belt driven. The
vacuum pump provides vacuum for the operation of
the wastegate for the turbocharger. The vacuum pump
does not require periodic maintenance, and is
serviced by replacement only.

Special Tools and Equipment

Engine Exhaust
Specifications
F asten er T ighten in g S p ecifications
Specifcation
Application
Metric English
Crossover Pipe to Manifold Bolt (Diesel Engine) 34 N*m 25 lb ft
Exhaust Hanger to Frame Crossmember Bolt 34 N*m 25 lb ft
Exhaust Hanger to Frame Nut 35 N-m 26 lb ft
Exhaust Manifold Nuts (Gasoline Engine) 65 N*m 48 lb ft
Exhaust Manifold Stud (Gasoline Engine) 22 N-m 16 lb ft
Exhaust V-Band Clamp (Diesel Engine) 12 N-m 106 lb in
Flange Stud Nuts (Diesel Engine) 64 N-m 47 lb ft
Flange Stud Nuts (Gasoline Engine) 64 N-m 47 lb ft
Tailpipe Hanger to Frame Nut 48 N-m 35 lb ft
U-Bolt Nuts 42 N*m 31 lb ft

GM SPO G roup N um bers

Application GM SPO Group Number
Exhaust Manifold Hanger 3.704
Exhaust Manifold Pipe 3.609
Exhaust Manifold Pipe Gasket 3.611
Exhaust Muffler (w/Exhaust Pipe and Tailpipe) 3.701
Heated Oxygen Sensor 3.682
Three-Way Catalytic Converter (w/Exhaust Manifold Pipe) 3.685

Diagnostic Information and Procedures

V ibration o r R attling
Step Action Value(s) Yes No
Check for loose and/or misaligned components.
1 — —
Are there any loose or misaligned components? Go to Step 2
1. Align the components.
2. Tighten the connections.
3. Check the following components for damage:
2 • The hangers — —
• The mounting brackets
• The clamps
Is the exhaust system vibrating or rattling? System OK

R estricted E xhaust
Step Action Value(s) Yes No
Inspect the exhaust tubing.
1 —
Is the exhaust tubing kinked? Go to Step 2 Go To Step 3
If possible, repair the damaged exhaust tubing. Otherwise,
2 replace the exhaust tubing. —
Is the exhaust system restricted? Go to Step 3 System OK
Inspect the muffler.
3 —
Is the muffler restricted? Go to Step 4 Go to Step 5
 R estricted E xhaust (c o n t’d)
Step Action Value(s) Yes No
1. If a restriction is likely, remove the muffler and
visually inspect it.
4 2. If the damage to the muffler is not repairable, replace —
the muffler.
Is the exhaust system restricted? Go to Step 5 System OK
Inspect the end of the tailpipe.
5 —
Is the end of the tailpipe obstructed? Go to Step 6 Go to Step 7
Remove the obstruction, or if the end of the tailpipe is
6 crimped, straighten the outlet. —
Is the exhaust system restricted? Go to Step 7 System OK
Inspect the catalytic converter for obstructions, which may
7 have occured as a result of a serious engine manlfunction. — —
Is the catalytic converter obstructed? Go to Step 8

1. Replace the catalytic converter.

8 2. Correct the engine malfunction. — _ _

Is the exhaust system restricted? System OK

Exhaust Leakage (N ot O B D II)

Step Action Value(s) Yes No
Inspect the exhaust component pipes and the couplings
for leaks.
1 —
Are there leaks at the exhaust component pipes and the
couplings? Go to Step 2 Go to Step 3
Tighten the clamps or fasteners to the specified torque.
2 Refer to Fastener Tightening Specifications. —
Is the exhaust system leaking or making noise? Go to Step 3 System OK
Inspect the components for misalignment or incorrect
3 installation. —
Are the components misaligned or improperly installed? Go to Step 4 Go to Step 5
Align the components and tighten the connections.
4 —
Is the exhaust system leaking or making noise? Go to Step 5 System OK
Inspect the exhaust manifold for cracks or damage.
5 —
Is the exhaust manifold cracked or broken? Go to Step 6 Go to Step 7
Replace the exhaust manifold.
6 —
Is the exhaust system leaking or making noise? Go to Step 7 System OK
Inspect the system for a leak between the exhaust
manifold and the cylinder head.
7 —
Is there a leak between the exhaust manifold and the
cylinder head? Go to Step 8 Go to Step 9
Tighten the manifold to cylinder head nuts and bolts to
specifications.
8 —
Refer to Fastener Tightening Specifications.
Is the exhaust system leaking or making noise? Go to Step 9 System OK
Inspect the seal for damage or excessive wear.
9 —
Are the seals damaged or worn? Go to Step 10 Go to Step 11
Replace the seals or gaskets, as necessary.
10 —
Is the exhaust system leaking or making noise? Go to Step 11 System OK
Inspect the exhaust pipe for burns or rust.
11 —
Is the exhaust pipe burned or rusted out? Go to Step 12 Go to Step 13
Replace the exhaust pipe.
12 —
Is the exhaust system leaking or making noise? Go to Step 13 System OK
 E xhaust Leakage (N o t O B D II) (co n t’d)
Step Action Value(s) Yes No
Inspect the muffler for damage.
13 —
Is the muffler burned or blown out? Go to Step 14 Go to Step 15
Replace the muffler assembly.
14 —
Is the exhaust system leaking or making noise? Go to Step 15 System OK
Inspect the condition of the clamps and/or brackets.
15 — —-
Are the clamps and/or brackets broken or loose? Go to Step 16
Repair or replace the damaged clamps and/or brackets, as
16 necessary. — —
Is the exhaust system leaking or making noise? System OK

Repair Instructions
E x h a u s t S y s te m In s p e c tio n The exhaust system (including the heat shield) must
be free of the following conditions:
Inspect the exhaust pipes, the catalytic converter(s), • Leaks
the muffler, and the tailpipe for the following conditions: • Binding
• Cracked joints • Grounding
• Excessive vibration
• Broken welds
These conditions may occur if any of the following
• Corrosion damage (Corrosion damage could components are loose or damaged:
cause leaks in the exhaust system.) • Flange bolts or flange nuts
Inspect the clamps, the brackets, and the insulators • Heat shields
for the following conditions: • Brackets
• Pipes
• Broken bolts
If any of these conditions exist, inspect the exhaust
• Stripped bolt threads system alignment. Align and replace any components
necessary, including new manifold seals, nuts, and
• Corroded bolts
gaskets.
C a ta ly tic C o n v e rte r R e p la c e m e n t
(G a s o lin e B e lo w 8 6 0 0 lb G V W R )

R em oval Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle.
2. Disconnect the oxygen sensor electrical
connections.

3. Remove the nuts from the Y-pipe flat flange.

4. Remove the Y-pipe and the catalytic converter
assembly.

5. Remove the nuts and the flange seals from the

Y-pipe and the exhaust manifold.
 Installation P rocedure
N o t i c e : Refer to Fastener Notice in Caution and
Notices.
1. Install the new flange seals and the new nuts to
the exhaust manifold.
Tighten
Tighten the nuts to 65 N-m (48 lb ft).

78428

2. Position the Y-pipe and the catalytic converter

assembly to the flat flange.
3. Install the nuts to the flat flange studs.
Tighten
Tighten the nuts to 64 N-m (47 lb ft).

412920

4. Connect the oxygen sensor electrical connections.

5. Check for clearance and alignment.
6. Lower the vehicle.
C a ta ly tic C o n v e r te r R e p la c e m e n t
(G a s o lin e A b o v e 8 6 0 0 lb G V W R )

R em oval P rocedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle
2. Disconnect the oxygen sensor electrical
connections.

3. Remove the nuts from the Y-pipe flat flange.

4. Remove the nuts and the flange seals from the

Y-pipe and the exhaust manifold.
 5. Remove the Y-pipe and the catalytic converter
assembly.
6. Remove the muffler and the catalytic converter
assembly.

Installation P rocedure
N o t i c e : Refer to Fastener Notice in Cautions and
Notices.
1. Install the flange seals and the nuts to the
exhaust manifold.
Tighten
Tighten the nuts to 65 N-m (48 lb ft).

2. Install the muffler and the catalytic converter

assembly.
3. Position the Y-pipe and the catalytic converter
assembly to the flat flange.
4. Install the nuts to the flat flange studs.
Tighten
Tighten the nuts to 64 N-m (47 lb ft).
 5. Connect the oxygen sensor electrical connections.
6. Check for clearance and alignment.
7. Lower the vehicle.

C a ta ly tic C o n v e rte r R e p la c e m e n t (D ie s e l)

R em oval Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle.
2. Remove the front exhaust pipe flange stud nuts
from the front of the catalytic converter assembly.
Remove the clamp from the exhaust
manifold pipe.

3. Remove the U-bolt from the rear of the catalytic

converter assembly.

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 4. Remove the catalytic converter from the muffler
assembly.

Installation P rocedure
1. Install a new flange gasket and the catalytic
converter to the front exhaust pipe flange studs.

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N o t i c e : Refer to Fastener Notice in Cautions and

Notices.

2. Install the nuts to the exhaust pipe flange studs.

Tighten
Tighten the nuts to 64 N-m (47 lb ft).

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 3. Install a new U-bolt to the rear of the catalytic
converter.
Tighten
Tighten the nuts to 42 N-m (31 lb ft).
Install the clamp to the exhaust manifold pipe.
Tighten
Tighten the nut to 12 N-m ( 106 lb in).
4. Check for clearance and alignment.
5. Lower the vehicle.

C a ta ly tic C o n v e r te r R e p la c e m e n t
(G a s , E x p o rt)

R em oval P rocedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle General
Information.
2. Remove the nuts from the Y-pipe flat flange.
3. Remove the muffler and the catalytic converter
assembly.

4. Remove the nuts, studs, and flange seals from

the Y-pipe and the exhaust manifold.
Installation Procedure
1. Install the new flange seals.
N o t i c e : Refer to Fastener Notice in Cautions and
Notices.
2. Install the new studs.
Tighten
Tighten the studs to 22 N-m (16 lb ft).
3. Install the new nuts connecting the Y-pipe,
catalytic converter assembly to the exhaust
manifold.
Tighten
Tighten the nuts to 64 N-m (47 lb ft).

4. Position the Y-pipe and the catalytic converter

assembly to the flat flange.
5. Install the nuts to the flat flange studs.
Tighten
Tighten the nuts to 64 N-m (47 lb ft).
6. Check for clearance and alignment.
7. Lower the vehicle.
Description and Operation
E x h a u s t S y s te m D e s c rip tio n
General Description
Exhaust system designs vary according to the engine
designation and intended use of the vehicle.
The exhaust pipe(s), muffler(s), and tailpipes are
standard equipment. The exhaust system uses a ball
joint coupling in order to secure the exhaust pipe
to the engine manifold.
Other connections on the gasoline engine use a flat
flange and gasket, while the diesel engine uses a slip
joint coupling design with a clamp and U-bolt.
The exhaust system is suspended by hangers attached
to the frame members. These allow some movement
of the exhaust system and minimize the transfer
of noise and vibration into the vehicle.
Catalytic Converters
The catalytic converter is an emission control device
added to the engine exhaust system to reduce
hydrocarbon, carbon monoxide and nitrogen oxide
pollutants from the exhaust gases. The catalyst in the
converter is not serviceable.
Heat shields are used to protect the vehicle and the
environment from high temperatures developed by the
exhaust system, especially the catalytic converter.
Notice: The catalytic converters require the use
of unleaded fuel only. Using leaded fuel will damage
the catalytic converters and other emission system
components.
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The catalytic converter(s) used on gasoline engine
vehicles with Light Duty Emissions (vehicles
below 8,600 lb GVWR) are part of the Y-pipe and are
attached forward of the flat flange.

The catalytic converter(s) used on gasoline engine

vehicles with Heavy Duty Emissions (vehicles above
8,600 lb GVWR) are both part of the Y-pipe
assembly and the muffler assembly. One converter is
attached forward of the flat flange and the second
converter is mounted rearward of the flat flange.

The diesel engine uses a catalytic converter, added to
the exhaust system in order to reduce smoke
(particulates). The catalytic converter operates at
normal exhaust system temperature; there is no
significant temperature increase as a result of oxidation
of particles.
Individual exhaust system replacement components
versus one complete assembly will vary upon
body/chassis and engine designation.
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R em oving Exhaust Parts
Caution: Always wear protective goggles and
gloves when removing exhaust parts as falling rust
and sharp edges from worn exhaust components
could result in serious personal injury.
When removing exhaust components, an accumulation
of dirt and corrosion can make work difficult. Using
a penetrating oil on the threads of bolts can assist in
the removal of these components.
In stalling Exhaust Parts
Notice: When jacking or lifting the vehicle from the
frame side rails, make sure the lift pads do not contact
the catalytic converter as converter damage will
result.
Important:
• Apply sealer GM P/N 9985020 or equivalent to all
slip joint connections.
• When installing the exhaust pipe to the engine
manifold, always use a new seal and nuts.
Clean the engine manifold stud threads with a
wire brush before installing the new nuts.
When installing a new exhaust pipe, muffler, or
tailpipe, on any model, check for proper alignment.
Rattles and noise vibrations in the exhaust system are
usually caused by the misalignment of parts. When
aligning the system, leave all bolts and nuts loose until
all parts are properly aligned. Tighten the exhaust
system components starting with the flat flange, then
the engine, and finally the U-bolts,if equipped.
Damaged exhaust system hangers, hanger brackets,
and clamps should be replaced to maintain exhaust
system alignment.