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Home › Pontiac › 2008 › G8 Base › Repair and Diagnosis › Engine Mechanical › Engine Exhaust System › Repair Instructions › Exhaust Crossover Pipe Replacement › Installation Procedure

Installation Procedure

  1. Clean all threads and flange faces of the intermediate exhaust system.
  2. Always check the condition of the catalytic converter to intermediate pipe flange gaskets and replace as necessary.
  3. Install the left post-catalytic converter HO2S to the intermediate exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 or Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 .
  4. Install the right post-catalytic converter HO2S to the intermediate exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 or Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 .
    5. NOTE: Refer to Exhaust System Inspection Notice .
    NOTE: Refer to Exhaust Service Caution .
  5. Position the intermediate exhaust assembly to the vehicle using a suitable jack.
    6. Fig 1: Identifying Center Insulator Hanger Bracket To Differential Retaining Bolt
    GM1947047Courtesy of GENERAL MOTORS CORP.
  6. Attach the intermediate exhaust assembly (2) by installing the center insulator hanger bracket to differential retaining bolt (1).
  7. Tighten the intermediate exhaust assembly to rear muffler retaining bolts.

    Tighten:  Tighten the bolts to 45 N.m (33 lb ft).

    8. Fig 2: Identifying Intermediate Exhaust Assembly To Right Catalytic Converter Retaining Nuts
    GM1947044Courtesy of GENERAL MOTORS CORP.
  8. Align the intermediate exhaust assembly (2) to the right catalytic converter (1).
    9. NOTE: Refer to Fastener Notice .
  9. Tighten the intermediate exhaust assembly to right catalytic converter retaining nuts (3).

    Tighten:  Tighten the nuts to 40 N.m (30 lb ft).

    10. Fig 3: Identifying Intermediate Exhaust Assembly To Left Catalytic Converter Retaining Nuts
    GM1947042Courtesy of GENERAL MOTORS CORP.
  10. Align the intermediate exhaust assembly (2) to the left catalytic converter (1).
  11. Tighten the intermediate exhaust assembly to left catalytic converter retaining nuts (3).

    Tighten:  Tighten the nuts to 40 N.m (30 lb ft).

    12. Fig 4: Identifying Right Post-Catalytic Converter HO2S Electrical Connector
    GM1949877Courtesy of GENERAL MOTORS CORP.
  12. Connect the right post-catalytic converter HO2S electrical connector (1).
    13. Fig 5: Identifying Left Post-Catalytic Converter HO2S Electrical Connector
    GM1949882Courtesy of GENERAL MOTORS CORP.
  13. Connect the left post-catalytic converter HO2S electrical connector (1).
    14. Fig 6: Identifying Left Rear Muffler To Intermediate Exhaust Assembly Retaining Bolts
    GM1947045Courtesy of GENERAL MOTORS CORP.
  14. Connect the left rear muffler (1) to the intermediate exhaust assembly (2).
    15. NOTE: Refer to Fastener Notice .
  15. Install the left rear muffler to intermediate exhaust assembly retaining bolts (3).

    Tighten:  Tighten the bolts to 45 N.m (33 lb ft).

  16. Make sure that the exhaust system is clear of all other components and chassis. If the exhaust system is not clear of all the other components loosen all retaining nuts and re-align. Refer to Exhaust System Alignment (LY7 and L98 Engines) .
  17. Lower the vehicle to the ground.
  18. Connect the battery ground cable to the battery. Refer to Battery Negative Cable Disconnection and Connection .
  19. If re-programming is required. Refer to Control Module References .
  20. Perform diagnostic system check using diagnostic scan tool, clear all relative DTCs and inspect the system for correct operation.
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