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‌SPECIFICATIONS

FASTENER SPECIFICATIONS

ENGINE

Exhaust - Volt

Single Use Non-Threaded Fasteners/Components

Single Use Threaded Fastener/Component Tightening Specifications

Reusable Threaded Fastener Tightening Specifications

DIAGNOSTIC INFORMATION AND PROCEDURES

SYMPTOMS - ENGINE EXHAUST

Review the Exhaust System Description and Operation in order to familiarize yourself with the system functions. Refer to Exhaust System Description .

All diagnostics on a vehicle should follow a logical process. Strategy Based Diagnostics is a uniform approach for repairing all systems. The diagnostic flow is the place to start when repairs are necessary and may always be used in order to resolve a system problem.

Visual/Physical Inspection

Inspect for aftermarket or non-OEM devices such as, but not including; tailpipe extensions, headers, and exhaust cutouts. This could affect the operation and proper performance of the exhaust system.

Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM, engine temperature, engine load, and frequency of concern.

Inspect the easily accessible or visible system components for obvious damage or conditions, which could cause any symptom.

Intermittents

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating as designed.

Symptom List

Loss of power - Refer to Restricted Exhaust .

Poor acceleration - Refer to Restricted Exhaust .

Poor fuel economy - Refer to Restricted Exhaust .

Excessive smoke-diesel - Refer to Restricted Exhaust. Exhaust hissing noise - Refer to Exhaust Leakage.

Exhaust popping noise - Refer to Exhaust Leakage. Exhaust rattle noise - Refer to Exhaust Noise.

Loud Exhaust noise - Refer to Exhaust Noise .

Exhaust buzz, groan, hum noise - Refer to Exhaust Noise .

RESTRICTED EXHAUST

Diagnostic Aids

A quick check of exhaust flow will help determine for gasoline engines.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

3

The exhaust system has very low back pressure under normal conditions. If the exhaust system is restricted, a significant increase in the exhaust pressure is noticed on the exhaust back pressure gauge.

Removing the heated oxygen sensor may set a DTC. When finishing this diagnostic table, be sure to clear all codes.

4

This step will isolate the catalytic converter from the remainder of the exhaust system.

7

Confirming that the condition has been fixed is essential. If the symptom still exists and the vehicle has a dual exhaust system, proceed to Step 2 and repeat diagnostic procedure on the opposite exhaust pipe.

EXHAUST LEAKAGE

EXHAUST NOISE

REPAIR INSTRUCTIONS

EXHAUST FRONT PIPE REPLACEMENT

Removal Procedure

WARNING: Protective Goggles and Glove Warning WARNING: Exhaust Service Warning

1. Raise and support the vehicle. Lifting and Jacking the Vehicle

Fig. 1: Exhaust Pipe And Gasket

Courtesy of GENERAL MOTORS COMPANY

CAUTION: Do not bend the exhaust flex pipe more than 10 degrees in any direction. Bending of more than 10 degrees or twisting in a range of ±0.5 degrees will damage the exhaust flex decoupler.

2. Remove Exhaust Front Pipe Nut (5)

3. Loosen Exhaust Pipe Clamp (4)

4. Remove Exhaust Front Pipe (2)

5. Remove and DISCARD the gasket.(1)

Installation Procedure

Fig. 2: Exhaust Pipe And Gasket

Courtesy of GENERAL MOTORS COMPANY

1. Install a NEW gasket.(1)

NOTE: The knob on the exhaust pipe (4) has to be in the gap of the exhaust front pipe.

2. Install Exhaust Front Pipe (2)

CAUTION: Fastener Caution

3. Install Exhaust Front Pipe Nut (3) and tighten 22 N.m (16 lb ft)

4. Exhaust Pipe Clamp (4) - Tighten 55 N.m (41 lb ft)

5. Lower the vehicle.

THREE-WAY CATALYTIC CONVERTER REPLACEMENT

Removal Procedure

WARNING: Protective Goggles and Glove Warning WARNING: Exhaust Service Warning

1. Remove Heated Oxygen Sensor Replacement - Sensor 1

2. Remove Heated Oxygen Sensor Replacement - Sensor 2

3. Remove Catalytic Converter Heat Shield Replacement

4. Raise and support the vehicle. Lifting and Jacking the Vehicle

Fig. 3: Exhaust Front Pipe, Nuts And Gasket Courtesy of GENERAL MOTORS COMPANY

CAUTION: Do not bend the exhaust flex pipe more than 10 degrees in any direction. Bending of more than 10 degrees or twisting in a range of ±0.5 degrees will damage the exhaust flex decoupler.

5. Remove Exhaust Front Pipe Nut (3)

6. Remove Exhaust Front Pipe (2)

7. Remove and DISCARD the gasket.(1)

Fig. 4: Catalytic Converter Bracket Nut And Bolt Courtesy of GENERAL MOTORS COMPANY

8. Remove Catalytic Converter Bracket Nut (2)

9. Remove Catalytic Converter Brace Bracket Bolt (1)

Fig. 5: Catalytic Converter And Catalytic Converter Rear Heat Shield Courtesy of GENERAL MOTORS COMPANY

10. Lower the vehicle.

11. Remove Catalytic Converter Nut (4) and DISCARD

12. Remove Catalytic Converter (3) & Catalytic Converter Bracket (6)

13. Remove Catalytic Converter Rear Heat Shield Bolt (2)

14. Remove Catalytic Converter Rear Heat Shield (1)

15. Remove the catalytic converter gasket.(6)

Fig. 6: Catalytic Converter, Bracket And Nuts Courtesy of GENERAL MOTORS COMPANY

16. Remove Catalytic Converter Brace Bracket Nut (3)

17. Remove Catalytic Converter Bracket (2) @Catalytic Converter (1)

Installation Procedure

Fig. 7: Catalytic Converter, Bracket And Nuts Courtesy of GENERAL MOTORS COMPANY

1. Install Catalytic Converter Bracket (2) @Catalytic Converter (1)

CAUTION: Fastener Caution

2. Install Catalytic Converter Brace Bracket Nut (3) and tighten 22 N.m (16 lb ft)

Fig. 8: Catalytic Converter And Catalytic Converter Rear Heat Shield Courtesy of GENERAL MOTORS COMPANY

3. Install a NEW catalytic converter gasket.(6)

4. Install Catalytic Converter Rear Heat Shield (1)

5. Install Catalytic Converter Rear Heat Shield Bolt (2) and tighten 9 N.m (80 lb in)

6. Install Catalytic Converter (3) & Catalytic Converter Bracket (6)

NOTE: Install NEW nuts.

7. Install Catalytic Converter Nut (4) and tighten 22 N.m (16 lb ft)

8. Raise the vehicle.

Fig. 9: Catalytic Converter Bracket Nut And Bolt Courtesy of GENERAL MOTORS COMPANY

9. Install Catalytic Converter Bracket Nut (2) and tighten 22 N.m (16 lb ft)

10. Install Catalytic Converter Brace Bracket Bolt (1) and tighten 22 N.m (16 lb ft)

Fig. 10: Exhaust Front Pipe, Nuts And Gasket Courtesy of GENERAL MOTORS COMPANY

11. Install a NEW gasket.(1)

12. Install Exhaust Front Pipe (2)

13. Install Exhaust Front Pipe Nut (3) and tighten 22 N.m (16 lb ft)

14. Lower the vehicle.

15. Install Catalytic Converter Heat Shield Replacement

16. Install Heated Oxygen Sensor Replacement - Sensor 2

17. Install Heated Oxygen Sensor Replacement - Sensor 1

EXHAUST MUFFLER REPLACEMENT

Removal Procedure

WARNING: Protective Goggles and Glove Warning WARNING: Exhaust Service Warning

1. Raise and support the vehicle. Lifting and Jacking the Vehicle

Fig. 11: Exhaust Pipe Clamp And Exhaust Hanger Insulator Courtesy of GENERAL MOTORS COMPANY

2. Loosen Exhaust Pipe Clamp (1)

NOTE: Inspect the exhaust hanger insulator for cracks or excessive wear.

Replace the insulator if cracked or has excessive wear.

3. Install Exhaust Hanger Insulator (2)

4. Support the exhaust muffler.

Fig. 12: Exhaust Muffler Insulator Bolt Courtesy of GENERAL MOTORS COMPANY

5. Remove the 2 exhaust muffler insulator bolts (1).

Fig. 13: Intermediate Exhaust Hanger Insulator Courtesy of GENERAL MOTORS COMPANY

NOTE: Inspect the exhaust hanger insulator for cracks or excessive wear.

Replace the insulator if cracked or has excessive wear.

6. Remove the intermediate exhaust hanger insulator (3).

NOTE: A second technician is required.

7. Install Exhaust Muffler (4)

NOTE: Inspect the exhaust hanger insulator for cracks or excessive wear.

Replace the insulator if cracked or has excessive wear.

8. Remove the rear exhaust hanger insulator (2).

Installation Procedure

Fig. 14: Intermediate Exhaust Hanger Insulator Courtesy of GENERAL MOTORS COMPANY

1. Install the rear exhaust hanger insulator (2).

NOTE: A second technician is required.

2. Install Exhaust Muffler (4)

3. Install the intermediate exhaust hanger insulator (3).

NOTE: The knob on the exhaust pipe (1) has to be in the gap of the exhaust front pipe.

4. Align the exhaust system.

Fig. 15: Exhaust Muffler Insulator Bolt Courtesy of GENERAL MOTORS COMPANY

CAUTION: Fastener Caution

5. Install the 2 exhaust muffler insulator bolts (1) and tighten to 22 N.m (16 lb ft).

Fig. 16: Exhaust Pipe Clamp And Exhaust Hanger Insulator Courtesy of GENERAL MOTORS COMPANY

6. Install the exhaust hanger insulator (2).

7. Exhaust Pipe Clamp (1) - Tighten 55 N.m (41 lb ft)

8. Remove the support from the exhaust muffler.

9. Lower the vehicle.

CATALYTIC CONVERTER HEAT SHIELD REPLACEMENT

Removal Procedure

WARNING: Refer to Exhaust Service Warning .

WARNING: Refer to Protective Goggles and Glove Warning .

Fig. 17: Heated Oxygen Sensor-Sensor 2 Courtesy of GENERAL MOTORS COMPANY

1. Remove Heated Oxygen Sensor-Sensor 2 (1) Heated Oxygen Sensor Replacement - Sensor 2

Fig. 18: Heated Oxygen Sensor-Sensor 1 Courtesy of GENERAL MOTORS COMPANY

2. Remove Heated Oxygen Sensor-Sensor 1 (1)Heated Oxygen Sensor Replacement - Sensor 1

Fig. 19: Catalytic Converter Heat Shield Bolt Courtesy of GENERAL MOTORS COMPANY

3. Remove Catalytic Converter Heat Shield Bolt (1)

Fig. 20: Catalytic Converter Heat Shield-Rear Courtesy of GENERAL MOTORS COMPANY

4. Remove Catalytic Converter Heat Shield-Rear (1)

5. Remove Catalytic Converter Heat Shield-Front (2)

Installation Procedure

Fig. 21: Catalytic Converter Heat Shield-Rear Courtesy of GENERAL MOTORS COMPANY

1. Install Catalytic Converter Heat Shield-Front (2)

2. Install Catalytic Converter Heat Shield-Rear (1)

Fig. 22: Catalytic Converter Heat Shield Bolt Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

3. Install Catalytic Converter Heat Shield Bolt (1) and tighten 9 N.m (80 lb in)

Fig. 23: Heated Oxygen Sensor-Sensor 1 Courtesy of GENERAL MOTORS COMPANY

4. Install Heated Oxygen Sensor-Sensor 1 (1)Heated Oxygen Sensor Replacement - Sensor 1

Fig. 24: Heated Oxygen Sensor-Sensor 2 Courtesy of GENERAL MOTORS COMPANY

5. Install Heated Oxygen Sensor-Sensor 2 (1)Heated Oxygen Sensor Replacement - Sensor 2 REAR BODY EXHAUST HEAT SHIELD REPLACEMENT

Fig. 25: Rear Body Exhaust Heat Shield Courtesy of GENERAL MOTORS COMPANY

EXHAUST FRONT UNDERBODY HEAT SHIELD REPLACEMENT

Removal Procedure

1. Raise and support the vehicle. Lifting and Jacking the Vehicle

2. Remove Exhaust Muffler Replacement

Fig. 26: Underbody Front Air Deflector And Nut Courtesy of GENERAL MOTORS COMPANY

3. Remove Underbody Front Air Deflector Nut (2)

4. Remove Underbody Front Air Deflector (1)

Fig. 27: Exhaust Front Underbody Heat Shield And Retainer Courtesy of GENERAL MOTORS COMPANY

5. Remove Exhaust Front Underbody Heat Shield Retainer (2)

6. Remove Exhaust Front Underbody Heat Shield (1)

Installation Procedure

Fig. 28: Exhaust Front Underbody Heat Shield And Retainer Courtesy of GENERAL MOTORS COMPANY

1. Install Exhaust Front Underbody Heat Shield (1)

2. Install Exhaust Front Underbody Heat Shield Retainer (2)

Fig. 29: Underbody Front Air Deflector And Nut Courtesy of GENERAL MOTORS COMPANY

3. Install Underbody Front Air Deflector (1)

CAUTION: Fastener Caution

4. Install Underbody Front Air Deflector Nut (2) and tighten 3 N.m (27 lb in)

5. Install Exhaust Muffler Replacement

6. Lower the vehicle.

DESCRIPTION AND OPERATION

EXHAUST SYSTEM DESCRIPTION

NOTE: Use of non-OEM parts may cause driveability concerns.

The exhaust system carries exhaust gases, treated by the catalytic converter, through a resonator, if applicable and into the exhaust muffler where exhaust noise is lessened.

In order to secure the exhaust pipe to the exhaust manifold, a flange and seal-joint coupling is utilized. The exhaust system may utilize a slip-joint coupling design with a clamp and a U-bolt or a flange connection with a gasket.

Exhaust hangers and rubber insulators help to support the weight of the exhaust pipe along with insulating any exhaust system vibration, rattle, or noise.

Exhaust hangers also space the exhaust system away from the underbody of the vehicle and allows the exhaust system to expand as the exhaust system warms up.

Exhaust heat shields are used to protect the body and other components from damage due to the heat from the exhaust system.

The exhaust system may be comprised of the following components: Exhaust manifold with Catalytic Converter

Exhaust pipes

Catalytic converter Exhaust hangers

Exhaust heat shields

Exhaust isolators and rods Exhaust muffler

Exhaust resonator, if equipped Exhaust tail pipe, if equipped

Resonator

Some exhaust systems are equipped with a resonator. The resonator, located either before or after the muffler, allows the use of mufflers with less back pressure. Resonators are used when vehicle characteristics require specific exhaust tuning.

Catalytic Converter

The catalytic converter is an emission control device added to the engine exhaust system in order to reduce hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) pollutants from the exhaust gas.

The catalytic converter is comprised of a ceramic monolith substrate, supported in insulation and housed within a sheet metal shell. The substrate may be washcoated with 3 noble metals:

Platium (Pt)

Palladium (Pd)

Rhodium (Rh)

The catalyst in the converter is not serviceable.

Muffler

The exhaust muffler reduces the noise levels of the engine exhaust by the use of tuning tubes. The tuning tubes create channels inside the exhaust muffler that lower the sound levels created by the combustion of the engine.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS

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