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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1623 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST MANIFOLD PIPE REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure
WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Exhaust Manifold Pipe
    GM1856232Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW exhaust manifold pipe gasket onto the muffler studs.
  2. Install the exhaust manifold pipe.
    3. Fig 2: View Of Exhaust Manifold Pipe, Gasket, Bolt & Manifold
    GM1856228Courtesy of GENERAL MOTORS CORP.
  3. Install any necessary exhaust muffler insulators that were separated from the muffler.
  4. Using the transmission jack, raise the transmission slightly.
    5. CAUTION: Refer to Fastener Caution .
  5. Install the exhaust manifold pipe to exhaust manifold nuts and tighten to 50 N.m (37 lb ft).
    6. Fig 3: View Of Exhaust Muffler, Exhaust Manifold Pipe, Gasket & Nuts
    GM1856230Courtesy of GENERAL MOTORS CORP.
  6. Install the exhaust muffler to exhaust manifold pipe nuts (1) and tighten to 45 N.m (33 lb ft).
    7. Fig 4: View Of Transmission Support Crossmember & Bolts
    GM1856226Courtesy of GENERAL MOTORS CORP.
  7. Position the transmission support crossmember.
  8. Install the transmission support crossmember bolts and tighten to 95 N.m (70 lb ft).
    9. Fig 5: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  9. Using the transmission jack, lower the transmission onto the transmission support.
  10. Install the transmission mount to transmission support nuts and tighten to 40 N.m (30 lb ft).
  11. Remove the support from the transmission.
  12. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis) , Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) .
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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.