Page 1
Exhaust System Installation: Cat-Back Exhaust System
2007-08 Avalanche/Suburban/Yukon XL 5.3L GMT900
Single Side Exit
Twin Pro-Series 4.0” Tips / SPORT PN 14246 / TOURING PN 14247
Hydroformed Oval Tip / SPORT PN 14248 / TOURING PN 14249
Please take time to read and understand these installation instructions.
CORSA recommends that installation of this system be performed by a qualified service center or professional
muffler installer who has the necessary equipment, tools and experienced personnel. However, if you decide
to perform this install, the use of a hoist and an additional person will be required.
CAUTION:
Never work on a hot exhaust system. Allow time for the vehicle to cool. Always wear eye protection
when working under a vehicle.
Please confirm that all parts are present before beginning the factory exhaust system removal
and CORSA exhaust system installation.
Bill of Materials:
• Head Pipe Assembly
(16A
V4004)
• Touring Muffler 14661 or
Sport Muffler 14638
Recommended Tools:
• Safety Glasses
• 15mm socket and ratchet
• Chain style pipe cutter
• Grommet pullers
• V
ehicle Spare tire removal kit
• Soapy water
• Torque wrench
• Tailpipe Assembly
(16AV4005)
• Side Swept 4.0” Pro-Series Tip
Assembly (16TA3000) or
Hydroformed Tip Assembly
(16SE3006)
• Hardware Kit
(16TA7018)
Anti-Seize
Lubricant
Hardware Kit
(16T
A7018)
Head Pipe Assembly
(16A
V4004)
• (1) Packet Anti-Seize
Lubricant
Tailpipe Assembly
V4005)
(16A
Hydroformed Tip
Assembly (16SE3006)
Touring Muffler 14661
Sport Muffler 14638
Side Swept Pro-Series 4.0”
ip Assembly (16TA3000)
T
Page 2
Exhaust System Installation: Cat-Back Exhaust System
2007-08 Avalanche/Suburban/Yukon XL 5.3L GMT900
Single Side Exit
Twin Pro-Series 4.0” Tips / SPORT PN 14246 / TOURING PN 14247
Hydroformed Oval Tip / SPORT PN 14248 / TOURING PN 14249
Removal of Stock System:
1) Lower the spare tire by following the instructions in the owner’s manual.
2) Remove the heat shield using a 15mm socket and ratchet.
(See Fig’s A, B & C)
3) Place a chain style cutter around the tailpipe at the tunnel muffler exit and cut the tailpipe
at this location. (See Fig. D)
4) Remove the grommets from the tailpipe hangers using grommet pullers or similar device.
(See Fig’s E & F) NOTE: Using a soapy water solution on the grommet hole will make
the job easier.
5) Remove the tailpipe section from the vehicle by lifting the tailpipe over the rear axle and
backwards under the rear bumper. Be sure to move the rear differential vent hose out of the
way when performing this operation. (See Fig’s G & H)
6) Use a 15mm socket and ratchet to remove
the flange nuts at the flange connection of
the head-pipe. Then remove the grommet at
the hanger location and remove the tunnel
muffler section away from the vehicle. This
completes the removal of the stock system.
(See Fig’s I & J) NOTE: Using a soapy
water solution on the grommet hole will
make the job easier.
FIG. A
FIG. B
FIG. C FIG. D
FIG. G FIG. H
FIG. E FIG. F
FIG. I FIG. J
Page 3
Exhaust System Installation: Cat-Back Exhaust System
2007-08 Avalanche/Suburban/Yukon XL 5.3L GMT900
Single Side Exit
Twin Pro-Series 4.0” Tips / SPORT PN 14246 / TOURING PN 14247
Hydroformed Oval Tip / SPORT PN 14248 / TOURING PN 14249
Installation of CORSA Exhaust System:
NOTE: Apply the anti-seize lubricant (supplied) to the threads ONLY of all the clamps
and flange bolts. Failure to follow this procedure can cause nuts to seize on clamps
and potentially destroy threads. After applying anti-seize lubricant, be sure to
thoroughly clean hands as lubricant will tarnish stainless steel.
be tightened using a properly calibrated Torque Wrench. Using an air impact gun
will damage the clamp and reduce its ability to effectively seal the joint. It may
also cause the joint to separate thereby causing damage to your exhaust system
and your vehicle.
All clamps should
CLAMP
Position slot
90° off of bolt
1) Locate the CORSA Head Pipe assembly and slide the flange over the studs on the factory
flange. Use the nuts supplied with the CORSA hardware kit and tighten down to 30 Ft-lbs.
Insert the hanger in to the factory grommet.
(See Fig’s K, L & M)
Note: Using a soapy solution on the grommet hole will make the job easier.
2) Slide a supplied 3” TORCA clamp over the inlet of the CORSA muffler. Make sure the drain
hole is facing down. Slide the muffler onto the Head Pipe and pre-tighten the clamp.
(See Fig’s N, O & P)
3) Slide a supplied 3” TORCA clamp over the inlet of the CORSA Tailpipe. From the rear of the
vehicle slide the pipe over the axle while holding the rear differential vent hose out of the way.
Insert the pipe over the muffler exit and place the hangers into the factory grommets.
(See Fig’s Q, R, S, T & U)
Position
clamp at
end of
expanded
tube
FIG. K
FIG. O FIG. P FIG. Q FIG. R
FIG. L FIG. M FIG. N
Page 4
Exhaust System Installation: Cat-Back Exhaust System
2007-08 Avalanche/Suburban/Yukon XL 5.3L GMT900
Single Side Exit
Twin Pro-Series 4.0” Tips / SPORT PN 14246 / TOURING PN 14247
Hydroformed Oval Tip / SPORT PN 14248 / TOURING PN 14249
FIG. S FIG. T FIG. U
4) Replace the heat shield using a 15mm socket and ratchet.
5) Slide a 3” TORCA clamp over the tip assembly and place the tip onto the end of the tailpipe.
Pre-tighten the clamp at this time.
(See Fig’s V, W, X, Y & Z)
6) Starting from the front of the CORSA exhaust system tighten all TORCA
clamps to 45 ft-lbs using a torque wrench.
7) Replace the spare tire and its components to the pre-removal condition.
8) It is strongly suggested that all clamps be checked and
tightened after road testing the vehicle once the system has cooled.
FIG. W FIG. X
NOTE: During cold weather start-ups, you may experience an exhaust
sound that is deeper and louder in tone than usual. This is temporary
and will diminish to normal levels once your engine has reached its
normal operating temperature.
Immediately following the installation of your CORSA exhaust
NOTE:
system, you may experience a trace of smoke after initial start-up.
DO NOT be alarmed. The smoke is caused by the burning of a small
amount of forming oil residue used in the manufacturing process.
FIG. Y
FIG. V
FIG. Z
CORSA PERFORMANCE EXHAUST
EXHAUST SYSTEMS
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