GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Corvette 🢒 Engine 🢒 Engine Cooling 🢒 General Exhaust System Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

    in General Information.
  2. Raise the vehicle. Refer to Section 0A.
  3. Remove the underbody braces, if equipped. Refer to Section 10-3.

    4. Object Number: 13862 Size: SH
  4. Disconnect the HO2S electrical connector.

    5. Object Number: 13863 Size: SH
  5. Remove the bolt(s) retaining the three-way converter(s) to the exhaust pipe flange(s).

    6. Object Number: 13866 Size: SH
  6. Remove the bolts retaining the front exhaust hanger to the exhaust pipe.

    7. Object Number: 13867 Size: SH
  7. Remove the bolts retaining the rear exhaust hanger to the exhaust pipe.

    8. Object Number: 13870 Size: SH
  8. Remove the nuts retaining the exhaust muffler to the hanger.
  9. Remove the complete exhaust system.
  10. Support the exhaust system with a suitable jack.

Installation Procedure
  1. Support the exhaust system with a suitable jack.
  2. Install the exhaust system to the vehicle.

    3. Object Number: 13870 Size: SH
  3. Install the nuts retaining the exhaust muffler to the hanger. Finger tighten only.

    4. Object Number: 13867 Size: SH
  4. Install the bolts retaining the rear exhaust hanger to the exhaust pipe. Finger tighten only.

    5. Object Number: 13866 Size: SH
  5. Install the bolts retaining the front exhaust hanger to the exhaust pipe. Finger tighten only.

    6. Object Number: 13863 Size: SH
  6. Install the bolts retaining the TWC(s) to the exhaust pipe flange(s). Finger tighten only.

    7. Object Number: 13862 Size: SH
  7. Install the HO2S electrical connector.
  8. Align the exhaust system when all the nuts and bolts are loose. Check for proper clearances from the other components.

    9. Important: In order to avoid rattles and vibrations, tighten the fasteners from the front to the rear.

  9. Tighten the fasteners on the exhaust system.

    10. Tighten

        • Tighten the bolts retaining the TWC(s) to the exhaust pipe flange(s) to 20 N·m (15 lb ft).
        • Tighten the front and rear exhaust hanger bolts to 25 N·m (18 lb ft).
        • Tighten the nuts retaining the muffler to the hanger to 54 N·m (40 lb ft).

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  10. Remove the exhaust system support.
  11. Install the underbody braces, if equipped. Refer to Section 10-3
  12. Lower the vehicle.
  13. Connect the negative battery cable.

    14. Tighten
    Tighten the negative battery cable bolt to 15 N·m (11 lb ft).