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HOMESERVICE MANUALSCHEVROLET2006SUBURBAN K2500, 6.0 UREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1524 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSCATALYTIC CONVERTER REPLACEMENT (WITH LU3)INSTALLATION PROCEDURE
2006 Chevrolet Suburban K2500, 6.0 U

Installation Procedure

2006 Chevrolet Suburban K2500, 6.0 USECTION 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.
NOTE: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from as exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.
    Fig 1: View Of HO2S
    GM1876458Courtesy of GENERAL MOTORS CORP.
  1. If replacing the catalytic converter assembly, perform the following steps, otherwise proceed to step 4.
  2. If reinstalling the old sensors, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
    3. CAUTION: Refer to Fastener Caution .
  3. Install the HO2S (1-4) to the catalytic converter assembly and tighten to 42 N.m (31 lb ft).
    4. Fig 2: View Of Exhaust Manifold Nuts & Exhaust Seals
    GM1878342Courtesy of GENERAL MOTORS CORP.
  4. Install the NEW exhaust seals (2 and 3) as required.
  5. Install the catalytic converter assembly to the muffler.
  6. Install the catalytic converter assembly to the exhaust manifolds.
  7. Install the catalytic converter to exhaust manifold nuts (1) and tighten to 50 N.m (37 lb ft).
    8. Fig 3: View Of Catalytic Converter To Muffler Nuts
    GM1708705Courtesy of GENERAL MOTORS CORP.
  8. Install the catalytic converter to muffler nuts and tighten to 45 N.m (33 lb ft).
    9. Fig 4: Locating Various Connectors & Clips
    GM1876455Courtesy of GENERAL MOTORS CORP.
  9. For vehicles equipped with 4WD perform the following steps, for vehicles equipped with 2WD proceed to step 13.
  10. Connect the engine wiring harness electrical connector (6) to the left front HO2S electrical connector (7).
  11. Install the CPA retainer.
  12. Install the HO2S electrical connector clip to the fuel line clip (2).
    13. Fig 5: View Of Various Connectors & Clips
    GM1876454Courtesy of GENERAL MOTORS CORP.
  13. For vehicles equipped with 4WD perform the following steps, connect the engine wiring harness electrical connector (7) to the left front HO2S electrical connector (8).
  14. Install the left front CPA retainer.
    15. Fig 6: View Of Engine Wiring Harness Electrical Connector & HO2S Electrical Connector
    GM1876456Courtesy of GENERAL MOTORS CORP.
  15. Connect the engine wiring harness electrical connector (1) to the left rear HO2S electrical connector (2).
  16. Install the left rear HO2S electrical connector clip to the frame.
  17. Install the CPA retainer.
    18. Fig 7: View Of Engine Harness Clip & Electrical Connectors
    GM1876457Courtesy of GENERAL MOTORS CORP.
  18. Connect the engine wiring harness electrical connector (2) to the right rear HO2S electrical connector (1).
  19. Install the right rear CPA retainer.
  20. Install the right rear HO2S electrical connector clip to the engine harness clip (3).
  21. Connect the right front HO2S electrical connector (5) to the engine wiring harness electrical connector (4).
  22. Install the right front CPA retainer.
    23. Fig 8: View Of Oil Pan Skid Plate & Bolts
    GM1698082Courtesy of GENERAL MOTORS CORP.
  23. Install the transmission crossmember. Refer to Transmission Support Crossmember Replacement (2WD 1500/2500) or Transmission Support Crossmember Replacement (4WD 1500/2500) or Transmission Support Crossmember Replacement (2WD 2500 HD/3500) or Transmission Support Crossmember Replacement (4WD 2500 HD/3500) .
  24. Position the oil pan skid plate and install the oil pan skid plate bolts, if equipped and tighten to 28 N.m (21 lb ft).
  25. 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.