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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1268 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSCATALYTIC CONVERTER REPLACEMENT (4.3L)REMOVAL PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Removal Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Removal Procedure
WARNING: This page is about a different car, the 2008 GMC Sierra, 2008 GMC Cab & Chassis Sierra, 2008 Chevrolet Silverado, and 2008 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Oil Pan Skid Plate & Bolts
    GM1698082Courtesy of GENERAL MOTORS CORP.
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Remove the oil pan skid plate bolts and skid plate, if equipped.
  3. Remove the transmission crossmember. Refer to Transmission Support Crossmember Replacement (2WD 2500 HD/3500) or Transmission Support Crossmember Replacement (2WD 1500/2500) or Transmission Support Crossmember Replacement (4WD 1500/2500) or Transmission Support Crossmember Replacement (4WD 2500 HD/3500) .
    4. Fig 2: View Of Engine Harness Clip & Electrical Connectors
    GM1876457Courtesy of GENERAL MOTORS CORP.
  4. Remove the right front connector position assurance (CPA) retainer.
  5. Disconnect the right front heated oxygen sensor (HO2S) electrical connector (5) from the engine wiring harness electrical connector (4).
  6. Remove the right rear CPA retainer.
  7. Disconnect the engine wiring harness electrical connector (2) from the right rear HO2S electrical connector (1).
  8. Remove the right rear HO2S electrical connector clip from the engine harness clip (3).
    9. Fig 3: View Of Engine Wiring Harness Electrical Connector & HO2S Electrical Connector
    GM1876456Courtesy of GENERAL MOTORS CORP.
  9. Remove the left rear CPA retainer.
  10. Disconnect the engine wiring harness electrical connector (1) from the left rear HO2S electrical connector (2).
  11. Remove the left rear HO2S electrical connector clip from the frame.
    12. Fig 4: View Of Various Connectors & Clips
    GM1876454Courtesy of GENERAL MOTORS CORP.
  12. For vehicles equipped with 2 wheel drive (2WD) perform the following steps, for vehicles equipped with 4 wheel drive (4WD) proceed to step 15.
  13. Remove the left front CPA retainer.
  14. Disconnect the left front HO2S electrical connector (7) from the engine wiring harness electrical connector (6).
    15. Fig 5: View Of Various Connectors & Clips
    GM1876455Courtesy of GENERAL MOTORS CORP.
  15. For vehicles equipped with 4WD perform the following steps, remove the left front CPA retainer.
  16. Disconnect the engine wiring harness electrical connector (7) from the left front HO2S electrical connector (8).
  17. Remove the left front HO2S electrical connector clip from the fuel line clip (2).
    18. Fig 6: View Of Catalytic Converter To Muffler Nuts
    GM1708705Courtesy of GENERAL MOTORS CORP.
  18. Remove the catalytic converter to muffler nuts.
    19. Fig 7: View Of Exhaust Manifold Nuts & Exhaust Seals
    GM1878342Courtesy of GENERAL MOTORS CORP.
  19. Remove the catalytic converter to exhaust manifold nuts (1).
  20. Separate the catalytic converter assembly from the exhaust manifolds.
  21. Remove the catalytic converter assembly from the exhaust muffler.
  22. If replacing the catalytic converter assembly, perform the following steps, otherwise proceed to step 4 in the installation procedure.
  23. Remove the exhaust seals (2 and 3).
    24. Fig 8: View Of HO2S
    GM1876458Courtesy of GENERAL MOTORS CORP.
  24. Remove the HO2S (1-4) from the catalytic converter assembly.
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.