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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1748 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST SYSTEM REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure
WARNING: This page is about a different car, the 2009 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Exhaust System
    GM1215598Courtesy of GENERAL MOTORS CORP.
  1. While the exhaust system is on the floor complete the following:
    1. Apply a soapy solution to the following in order to ease the installation of the hangers:
      • The inner diameter of the front exhaust hangers
      • The exhaust pipe hanger rods
      • The inner diameter of the tail pipe hangers
      • The tail pipe hanger rods
    2. Press the front exhaust hangers over the exhaust pipe hanger rods.
  2. Place NEW seals on the exhaust manifold flanges.
    3. CAUTION: Refer to Exhaust System Inspection Caution .
  3. With the aid of an assistant, raise the exhaust system into position, aligning the exhaust pipe flanges with the studs located in the rear of the exhaust manifolds.
  4. Finger tighten the nuts to the exhaust manifold studs.
    5. Fig 2: Locating Tail Pipe Hangers
    GM772379Courtesy of GENERAL MOTORS CORP.
  5. Press the tail pipe hangers (1) over the tail pipe hanger rods.
    6. Fig 3: Locating Front Exhaust Hangers
    GM772376Courtesy of GENERAL MOTORS CORP.
  6. Press the front exhaust hangers (1) over the rear suspension hanger rods.
    7. Fig 4: View Of Exhaust Pipe-To-Exhaust Manifold Nuts
    GM772367Courtesy of GENERAL MOTORS CORP.
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.