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 775 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSCATALYTIC CONVERTER REPLACEMENT (3.8L)REMOVAL PROCEDURE

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

Removal Procedure

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

WARNING: This page is about a different car, the 2003 Buick Regal and 2003 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.

IMPORTANT: The three way catalytic converter is serviced by replacing the entire assembly. Always replace the gaskets at the front and rear flanges when servicing the three way catalytic converter. Never install the original gasket.

Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
Disconnect the heated oxygen sensor (HO2S) electrical connector.
Remove the exhaust manifold pipe stud nuts.

Fig 1: Removing Exhaust Manifold Pipe Nuts
Courtesy of GENERAL MOTORS CORP.
Remove the exhaust manifold pipe gasket.
Support the exhaust system.
Remove the catalytic converter nuts.

Fig 2: Removing Catalytic Converter Nuts
Courtesy of GENERAL MOTORS CORP.
Remove the catalytic converter hangers.

Fig 3: Removing Catalytic Converter Hangers
Courtesy of GENERAL MOTORS CORP.
Remove the 3-way catalytic converter.
Remove the catalytic converter gasket.
Clean and inspect the exhaust manifold and the exhaust pipe gasket mating surfaces.
Remove the heated oxygen sensor (HO2S). Refer to HEATED OXYGEN SENSOR in Removal & Installation.

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.