GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Corvette 🢒 General Information 🢒 General Information 🢒 Exhaust System Replacement

Removal Procedure

    Object Number: 67893 Size: SH
  1. Raise the vehicle and support. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the stabilizer shaft bolts, nuts and clamps from the rear crossmember.
  3. Position the stabilizer shaft downward.

    4. Object Number: 64013 Size: SH
  4. Remove the intermediate exhaust pipe-to-rear pipe bolts.

    5. Object Number: 64009 Size: SH
  5. Remove the LH muffler from the muffler hanger.
  6. Remove the LH muffler from the vehicle.
  7. Remove the RH muffler from the muffler hanger.
  8. Remove the RH muffler hanger.
  9. Remove the RH muffler from the vehicle.

    10. Object Number: 53685 Size: SH
  10. Disconnect the rear heated oxygen sensor (HO2S) connectors.

    11. Object Number: 64015 Size: SH
  11. Remove the takedown pipe-to-exhaust manifold flange nuts.

    12. Object Number: 64016 Size: SH
  12. Remove the front exhaust hanger bolts from the takedown pipe bracket.

    13. Object Number: 64010 Size: SH
  13. Remove the rear exhaust hanger bolts from the rear intermediate exhaust pipes.

    14. Object Number: 67889 Size: SH
  14. Remove the intermediate pipe assembly from the vehicle.
  15. Remove the rear HO2S from the intermediate pipe.

Installation Procedure
  1. Coat the threads of the heated oxygen sensor with anti-sieze compound G/M P/N 5613695, or equivalent if necessary.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the rear HO2S to the intermediate pipe.

    3. Tighten
    Tighten the rear HO2S to 41 N·m (30 lb ft).


    Object Number: 67889 Size: SH
  3. Install the intermediate pipe assembly to the vehicle.
  4. By hand start the following exhaust system nuts and bolts:
    5. • The rear exhaust hanger bolts
    • The takedown pipe flange nuts
    • The intermediate exhaust pipe to the rear intermediate exhaust pipe bolts
    • The takedown pipe hanger bolts
    • Install the RH muffler hanger.

    Object Number: 64009 Size: SH
  5. Install the RH muffler to the vehicle.
  6. Install the RH muffler to the muffler hanger.
  7. Install the LH muffler to the vehicle.
  8. Install the LH muffler to the muffler hanger.

    9. Object Number: 67893 Size: SH
  9. Reposition the stabilizer shaft to the rear crossmember.
  10. Install the stabilizer shaft clamps, nuts and bolts. Refer to Stabilizer Shaft Replacement in Rear Suspension.
  11. Inspect the alignment of the exhaust system. Refer to Exhaust System Clearances .
  12. Tighten the exhaust system bolts starting at the rear and finishing with the front exhaust hanger.

    13. Tighten

    1. Tighten the intermediate exhaust pipe to rear exhaust pipe bolts to 50 N·m (37 lb ft).
    2. Tighten the rear exhaust hanger bolts to 50 N·m (37 lb ft).
    3. Tighten the exhaust manifold-to-takedown pipe nuts to 20 N·m (15 lb ft).
    4. Tighten the takedown pipe hanger bolts to 50 N·m (37 lb ft).

    Object Number: 53685 Size: SH
  13. Connect the rear HO2S connectors.
  14. Lower the vehicle.