Catalytic Converter Replacement Diesel

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



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.



4. Remove the catalytic converter from the muffler assembly.

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




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.

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

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




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.

Catalytic Converter Replacement Gas, Export

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in 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.

1. Install the new flange seals.

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.

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.

Catalytic Converter Replacement Gas, 8600 lb and above (GVWR)

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, studs and 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.

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.

1. Install the flange seals, the studs and the nuts connecting the Y-pipe, catalytic converter assembly to the exhaust manifold.

Tighten
Tighten the studs to 22 N·m (16 lb ft).

Tighten
Tighten the nuts to 64 N·m (47 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.

Catalytic Converter Replacement 4.8L and 5.3L Engines

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the engine shield bolts and shield, if necessary.



3. Remove the oil pan skid plate bolts and plate, if necessary.



4. Support the transmission with a suitable transmission jack.
5. Remove the transmission mount to transmission support nuts.
6. Raise the transmission off the transmission support.



7. Remove the transmission support crossmember bolts and nuts.
8. Remove the transmission support crossmember.



9. Unclip the oxygen sensor connection from the floor reinforcement.



10. Remove the clip from around the engine harness and the oxygen sensor pigtail.
11. Disconnect the connector position assurance (CPA) retainers.
12. Disconnect the oxygen sensor electrical connectors.



13. Unclip the oxygen sensors electrical connectors from the following:

•

Hose clip

•	Transmission crossmember

14. Disconnect the CPA retainers.
15. Disconnect the oxygen sensor electrical connectors (1, 2).



16. Remove the left exhaust manifold pipe nuts.



17. Remove the right exhaust manifold pipe nuts.



18. Remove the exhaust muffler nuts.
19. Remove the catalytic converter.



20. Remove the oxygen sensors if the catalytic converter is to be replaced.

Notice: Refer to Fastener Notice in the Preface section.




1. If the catalytic converter was replaced, perform the following:

1.1.	Apply anti-seize compound GM P/N 12377953 or equivalent to the threads of the old oxygen sensors.

1.2.	Install the oxygen sensors.

Tighten
Tighten the oxygen sensors to 42 N·m (31 lb ft).

2. Install the catalytic convertor.



3. Install NEW exhaust manifold pipe seals to the exhaust manifolds.
4. Install the right exhaust manifold pipe nuts until sung.



5. Install the left exhaust manifold pipe nuts until snug.
6. Tighten the right and left exhaust manifold pipe nuts.

Tighten
Tighten the nuts to 50 N·m (39 lb ft).




7. Install the exhaust muffler nuts.

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




8. Connect the oxygen sensor electrical connectors (1, 2).
9. Connect the CPA retainers.
10. Clip the oxygen sensors electrical connectors to the following:

•

Hose clip

•	Transmission crossmember




11. Connect the oxygen sensor electrical connectors.
12. Connect the CPA retainers.
13. Install the clip around the engine harness and the oxygen sensor pigtail.



14. Clip the oxygen sensor connection to the floor reinforcement.



15. Install the transmission support crossmember.
16. Install the transmission support crossmember bolts and nuts.

Tighten
Tighten the bolts to 95 N·m (70 lb ft).




17. Lower the transmission onto the transmission support.
18. Install the transmission mount to transmission support nuts.

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

19. Remove the transmission jack.



20. Install the oil pan skid plate and bolts, if necessary.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).




21. Install the engine shield and bolts, if necessary.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).

22. Lower the vehicle.