LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2012 >> Caprice 6.0 2 >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Exhaust Crossover Pipe Replacement >> Installation Procedure

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 , for 3.6L engine or Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 for 6.0L engine.
  4. Install the right post-catalytic converter HO2S to the intermediate exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 , for 3.6L engine or Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 for 6.0L engine.
    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 centre insulator hanger bracket to differential retaining bolt (1).
    7. Fig 2: Intermediate Exhaust Assembly And Front Exhaust Isolators
    GM2660734Courtesy of GENERAL MOTORS COMPANY
  7. Attach the intermediate exhaust assembly (2) into the exhaust isolators (1).
    8. CAUTION:

    Refer to Fastener Caution .

  8. Tighten the intermediate exhaust assembly to rear muffler fasteners (3) 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) and tighten the fasteners (3) to 40 N.m (30 lb ft).
    10. Fig 4: Identifying Intermediate Exhaust Assembly To Left Catalytic Converter Retaining Nuts
    GM1947042Courtesy of GENERAL MOTORS COMPANY
  10. Align the intermediate exhaust assembly (2) to the left catalytic converter (1) and tighten the fasteners (3) to 40 N.m (30 lb ft).
  11. Tighten the intermediate exhaust assembly to left catalytic converter retaining nuts (3).
    12. Fig 5: Identifying Oxygen Sensor & Wiring Harness Connector
    GM1949877Courtesy of GENERAL MOTORS COMPANY
  12. Connect the right post-catalytic converter HO2S electrical connector (1).
    13. Fig 6: Identifying HO2S Electrical Connector
    GM1949882Courtesy of GENERAL MOTORS COMPANY
  13. Connect the left post-catalytic converter HO2S electrical connector (1).
    14. Fig 7: Identifying Intermediate Exhaust Assembly To Rear Muffler Retaining Bolts
    GM1947045Courtesy of GENERAL MOTORS COMPANY
  14. Connect the left rear muffler (1) to the intermediate exhaust assembly (2).
  15. Install the left rear muffler to intermediate exhaust assembly and tighten the fasteners (3) to 45 N.m (33 lb ft).
  16. 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.
    17. Fig 8: Underbody Brace Fasteners
    GM2660737Courtesy of GENERAL MOTORS COMPANY
  17. Install the underbody brace (2) and tighten the fasteners (1) to 58 N.m (43 lb ft).
  18. Lower the vehicle to the ground.
  19. Connect the battery ground cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Primary) , Battery Negative Cable Disconnection and Connection (Auxiliary) .
  20. If re-programming is required. Refer to 72864.
  21. Perform diagnostic system check using diagnostic scan tool, clear all relative DTCs and inspect the system for correct operation.
scientia non olet · About LEMON Manuals