Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 342 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSCATALYTIC CONVERTER REPLACEMENT (3.8L)INSTALLATION PROCEDURE

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F

Installation Procedure

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Installation Procedure

WARNING: This page is about a different car, the 2002 Buick Regal and 2002 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.

Install the heated oxygen sensor (HO2S). Refer to HEATED OXYGEN SENSOR

Fig 1: Heated Oxygen Sensor (HO2S)

Courtesy of GENERAL MOTORS CORP.

Install a new exhaust manifold pipe gasket to the exhaust manifold pipe studs.
Install and support the 3-way catalytic converter.
Install the exhaust manifold pipe stud nuts.
Tighten

Tighten the nuts to 35 N.m (26 lb ft).

Fig 2: Exhaust Manifold Pipe Gasket To The Exhaust Manifold Pipe Studs
Courtesy of GENERAL MOTORS CORP.
Install the catalytic converter gasket.
Install the catalytic converter bolts.
Tighten

Tighten the bolts to 45 N.m (33 lb ft).

Fig 3: Catalytic Converter Gasket And Bolts
Courtesy of GENERAL MOTORS CORP.
Install the catalytic converter hangers.
Connect the heated oxygen sensor (HO2S) electrical connector and retainers. Refer to HEATED OXYGEN SENSOR
Remove the support from the exhaust system.
Inspect the exhaust system for leaks and underbody contact.
Lower the vehicle.

RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.