GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Tahoe - 2WD 🢒 Engine 🢒 Engine Exhaust 🢒 Exhaust Outlet Replacement

Removal Procedure

    Object Number: 668379 Size: SH
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the exhaust manifold pipe to exhaust outlet clamp.

    3. Object Number: 694896 Size: SH
  3. Remove the exhaust manifold pipe to catalytic pipe flange bolts.
  4. Slide the exhaust manifold pipe hanger from the insulator.
  5. Remove the exhaust pipe from the vehicle.

    6. Object Number: 702776 Size: SH
  6. If equipped with an automatic transmission, remove the transmission fluid fill tube to bell housing nuts.
  7. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.

    8. Object Number: 654525 Size: SH
  8. Remove the 3 bolts (1) retaining the right exhaust pipe to the exhaust manifold.

    9. Object Number: 668425 Size: SH
  9. Remove the lower bolt (2) retaining the heat shield to the exhaust outlet.
  10. Lower the vehicle.

    11. Object Number: 310799 Size: SH
  11. Move the hood to the service position by moving the hood hinge bolts (1) to the service positions (2).

    12. Object Number: 658266 Size: SH
  12. Remove the upper intake manifold sight shield using the following procedure:
    13. 12.1. Remove the retaining bolt in the front of the shield.
    12.2. Lift-up on the front of the shield.
    12.3. Lift the shield off the rear bracket.

    Object Number: 660382 Size: SH
  13. Remove the 3 bolts holding the heat shield to the turbocharger.
  14. Remove the turbocharger heat shield.

    15. Object Number: 668425 Size: SH
  15. Remove the remaining 2 bolts (1, 3) for the exhaust outlet heat shield.
  16. Remove the exhaust outlet heat shield.

    17. Object Number: 654540 Size: SH
  17. Remove the exhaust outlet 4 bolts and the 2 nuts.
  18. Remove the exhaust outlet and gasket from the turbocharger.
  19. Position the exhaust outlet to the side in order to access the right exhaust pipe to turbocharger bolts.

    20. The exhaust outlet cannot be removed until the right exhaust pipe is removed.


    Object Number: 654525 Size: SH
  20. Remove the 3 bolts (2) from the right exhaust pipe to the turbocharger.
  21. Remove the right exhaust pipe and gaskets.
  22. Remove the exhaust outlet out the bottom of the vehicle.

    23. Object Number: 663765 Size: SH
  23. Clean the exhaust outlet.
  24. Clean the exhaust outlet and turbocharger mating surfaces.
  25. Inspect the exhaust outlet for dents and cracks.
  26. Replace the exhaust outlet if any damage is found.

Installation Procedure

    Object Number: 654525 Size: SH
  1. From under the vehicle, position the exhaust outlet to rear of the engine Do not install the outlet to the turbocharger.
  2. Install the right exhaust pipe with NEW gasket to the turbocharger. Align the tabs on the gasket to face inward.

    3. 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.

  3. Install the exhaust pipe to turbocharger bolts (2).

    4. Tighten
    Tighten the exhaust pipe to turbocharger bolts to 53 N·m (39 lb ft).


    Object Number: 654540 Size: SH
  4. Install the exhaust outlet with a NEW gasket to the turbocharger.
  5. Install the exhaust outlet bolts and nuts.

    6. Tighten
    Tighten the exhaust outlet 4 bolts and 2 nuts to 53 N·m (39 lb ft)


    Object Number: 668425 Size: SH
  6. Install the exhaust outlet heat shield.
  7. Install the upper 2 exhaust outlet heat shield bolts (1, 3).

    8. Tighten
    Tighten the exhaust outlet heat shield bolts to 8 N·m (71 lb in).


    Object Number: 660382 Size: SH
  8. Install the turbocharger heat shield.
  9. Install the turbocharger heat shield bolts.

    10. Tighten
    Tighten the turbocharger heat shield bolts to 9 N·m (80 lb in).


    Object Number: 668425 Size: SH
  10. Raise the vehicle.
  11. Install the lower bolt (2) for the exhaust outlet heat shield.

    12. Tighten
    Tighten the exhaust outlet heat shield bolt to 8 N·m (71 lb in).


    Object Number: 702776 Size: SH
  12. If equipped with an automatic transmission, install the transmission fluid fill tube to bell housing nuts.

    13. Tighten
    Tighten the transmission fluid fill tube nuts 18 N·m (13 lb ft).


    Object Number: 654525 Size: SH
  13. Install the right exhaust pipe to the exhaust manifold with a NEW gasket. Align the tab on the gasket to face outward as shown.
  14. Install the right exhaust pipe to exhaust manifold bolts (1).

    15. Tighten
    Tighten the exhaust pipe to exhaust manifold bolts to 53 N·m (39 lb ft).


    Object Number: 694896 Size: SH
  15. Install the exhaust manifold pipe hanger in the insulator.
  16. Install the exhaust manifold pipe to the exhaust muffler pipe.
  17. Install the exhaust manifold pipe bolts.

    18. Tighten
    Tighten the exhaust manifold pipe bolts 40 N·m (30 lb ft).


    Object Number: 668379 Size: SH
  18. Install the exhaust outlet to exhaust manifold pipe clamp. Ensure the exhaust manifold pipe is square to the exhaust outlet.

    19. Tighten
    Tighten the exhaust manifold pipe clamp to 40 N·m (30 lb ft).

  19. Lower the vehicle.

    20. Object Number: 658266 Size: SH
  20. Install the upper intake manifold sight shield.

    21. Tighten
    Tighten the upper intake manifold shield bolt to 9 N·m (80 lb in).


    Object Number: 310799 Size: SH
  21. Position the hood in the normal operating position by moving the hood hinge bolts from service position (2) to normal operating position (1).

    22. Tighten
    Tighten the hood hinge bolts to 25 N·m (18 lb ft).

  22. Inspect for exhaust leaks.