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Home >> GMC >> 2006 >> Sierra 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 921 (Engine Exhaust System) >> Repair Instructions >> Catalytic Converter Replacement (4.8L, 5.3L, 6.0L, 6.2L) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 GMC Sierra and 2007 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: 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 Catalytic Converter Assembly HO2S's
    GM1704008Courtesy 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. NOTE: Refer to Component Fastener Tightening Notice .
    NOTE: Refer to Fastener Notice .
  3. Install the HO2S (1-5) to the catalytic converter assembly. (1500 series shown, 2500/3500 series similar).

    Tighten:  Tighten the sensors to 42 N.m (31 lb ft).

    4. Fig 2: View Of Catalytic Converter To Exhaust Manifold Nuts & Exhaust Seals
    GM1708626Courtesy of GENERAL MOTORS CORP.
  4. Install the NEW exhaust seals (2 and 3) as required. (1500 series shown, 2500/3500 series similar).
  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).

    Tighten:  Tighten the nuts to 50 N.m (37 lb ft).

  8. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis) .
    9. Fig 3: View Of Catalytic Converter To Muffler Nuts (RPO L92)
    GM1708979Courtesy of GENERAL MOTORS CORP.
  9. If the vehicle is a 2500/3500 series, install the muffler to catalytic converter nuts.

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

    10. Fig 4: View Of Catalytic Converter To Muffler Nuts
    GM1708705Courtesy of GENERAL MOTORS CORP.
  10. If the vehicle is a 1500 series, install the catalytic converter to muffler nuts.

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

    11. Fig 5: View Of Left Front HO2S Electrical Connector Clip & Engine Wiring Harness Electrical Connector
    GM1704004Courtesy of GENERAL MOTORS CORP.
  11. For vehicles equipped with a 4L60-E/4L70-E automatic transmission perform the following steps, for vehicles equipped with a 6L80-E automatic transmission proceed to step 13.
  12. Install the HO2S electrical connector clip (1) to the fuel line clip.
  13. Connect the engine wiring harness electrical connector (2) to the HO2S.
  14. Install the CPA retainer.
    15. Fig 6: View Of Engine Wiring Harness Electrical Connector Clip & Electrical Connector
    GM1704002Courtesy of GENERAL MOTORS CORP.
  15. Connect the engine wiring harness electrical connector (3) to the HO2S.
  16. Install the engine wiring harness electrical connector clip (1) to the fuel line clip.
  17. Install the CPA retainer (2).
    18. Fig 7: View Of Left Rear CPA Retainer & Engine Wiring Harness Electrical Connector
    GM1704005Courtesy of GENERAL MOTORS CORP.
  18. Connect the left rear HO2S electrical connector to the engine wiring harness electrical connector (3).
  19. Install the left rear CPA retainer (1).
    20. Fig 8: View Of Engine Wiring Harness Electrical Connectors, (CPA) Retainers & Engine Harness Clips
    GM1704006Courtesy of GENERAL MOTORS CORP.
  20. Install the right rear HO2S electrical connector clip to the engine harness clip (5).
  21. Connect the engine wiring harness electrical connector (3) to the right rear HO2S electrical connector.
  22. Install the right rear CPA retainer (4).
  23. Connect the right front HO2S electrical connector to the engine wiring harness electrical connector (1).
  24. Install the right front CPA retainer (2).
    25. Fig 9: View Of Oil Pan Skid Plate & Bolts
    GM1698082Courtesy of GENERAL MOTORS CORP.
  25. Install the transmission crossmember. Refer to Transmission Support Crossmember Replacement (2WD 1500/2500) or Transmission Support Crossmember Replacement (2WD 2500 HD/3500) or Transmission Support Crossmember Replacement (4WD 1500/2500) or Transmission Support Crossmember Replacement (4WD 2500 HD/3500) .
  26. Position the oil pan skid plate and install the oil pan skid plate bolts, if equipped.

    Tighten:  Tighten the bolts to 28 N.m (21 lb ft).

  27. Lower the vehicle.
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