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 690 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSMUFFLER REPLACEMENT (SINGLE)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 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

Install and support the exhaust muffler with exhaust pipe and tail pipe.
Install the exhaust hanger insulators to the exhaust muffler with exhaust pipe and tail pipe.

Fig 1: Exhaust Hanger Insulators, Muffler, Pipe & Tail Pipe
Courtesy of GENERAL MOTORS CORP.
Install the catalytic converter gasket.
NOTE: Refer to FASTENER NOTICE .
Install the catalytic converter bolts.
Tighten

Tighten the catalytic converter bolts to 45 N.m (33 lb ft).
Remove the support from the exhaust system.
Inspect the exhaust system for leaks and underbody contact.
Lower the vehicle.

Fig 2: Catalytic Converter Gasket & Bolts
Courtesy of GENERAL MOTORS CORP.

RENDER: 1.0x

NO RELATED

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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.