GM Duramax Diesel

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1 Please confirm that all parts are present before beginning the factory exhaust system removal and CORSA exhaust system installation BILL OF MATERIALS: PN 15201, 15203, & 15210: (1) Muffler, (1) Mid-Pipe, (1) Tailpipe, (1) Hydroformed Tip Kit, (3) 4 Clamps, (1) Gasket, (4) Nuts and (1) Packet Anti- Seize Lubricant / NOTE: PN & include (4) 4 Clamps & (1) Adapter pipe PN 15202: (1) Downpipe, (1) Gasket, (4) Nuts, (4) Bolts, (4) Washers and (1) Packet Anti- Seize Lubricant 16DT3005 PN Crew Cab / Short Box (w/o Downpipe) TAILPIPE PN CORSA 4 Downpipe DOWN PIPE 16DT4001 MID PIPE 16DT4004 PN 15203, Crew Cab / Long Box (w/o Downpipe) PN 15210, Crew Cab / Long Box DUALLY (w/o Downpipe) PN DT3007 PN DT3005 TAILPIPE ADAPTER PIPE 16DT4016 MID PIPE 16DT DT3005 PN Extended Cab / Short Box (w/o Downpipe) TAILPIPE MID PIPE 16DT4013 1

2 Please confirm that all parts are present before beginning the factory exhaust system removal and CORSA exhaust system installation BILL OF MATERIALS: PN 15205, & 15211: (1) Muffler, (1) Mid-Pipe, (1) Tailpipe, (1) Adapter Pipe (1) Hydroformed Tip Kit, (4) 4 Clamps & (1) Packet Anti-Seize Lubricant NOTE: PN includes (3) 4 Clamps & NO Adapter Pipe. 16DT3005 PN Crew Cab / Short Box (w/o Downpipe) HARDWARE KIT DT7018 TAILPIPE ASSEMBLY MID-PIPE ASSEMBLY 16DT DT3005 PN Crew Cab / Long Box (w/o Downpipe) HARDWARE KIT DT7019 TAILPIPE ASSEMBLY MID-PIPE ASSEMBLY 16DT4020 ADAPTER PIPE 16DT4016 PN 15211, Crew Cab / Long Box DUALLY (w/o Downpipe) HARDWARE KIT DT DT3007 TAILPIPE ASSEMBLY MID-PIPE ASSEMBLY 16DT4020 ADAPTER PIPE 16DT4016 2

3 PN 15201/15205 Crew Cab / Short Box (w/o Downpipe) PN 15203/15206 Crew Cab / Long Box (w/o Downpipe) PN 15210/15211 Crew Cab / Long Box Dually (w/o Downpipe) PN PN Extended Cab / Short Box (w/o Downpipe) CORSA 4 Downpipe Recommended Tools: Safety glasses, 15mm socket or wrench, 7/16 socket, 3/4 wrench, Torque wrench and WD40 or other lubricant. Air ratchet also recommended. CATALYTIC CONVERTER BACK EXHAUST SYSTEM REMOVAL: Removal Instructions: 1. Using a 15mm socket or wrench, loosen the (4) nuts on the muffler assembly/tailpipe section (See Fig. A). 2. Remove rubber isolators on muffler assembly/tailpipe section. (See Fig. B, C, D & E). Use a lubricant to facilitate removal. 3. Now muffler assembly/tailpipe section can be removed. REMOVAL (For PN 15201, 15203, & 15210) NOTE: Be sure to keep the rubber isolators as they will be needed for installation of the new exhaust system. Please be sure to review the attached instructions prior to beginning the installation process. If you have any questions about the enclosed parts, instructions or encounter a problem during installation, call CORSA Performance Technical Assistance at Do not attempt to make any modifications to parts as this will void your warranty. NOTE: IMPORTANT: Make sure that the small drain hole in the muffler faces down when installed. FIG. A FIG. B FIG. C FIG. D Removal Instructions: (For PN 15205, & 15211) 1. Use a 15mm wrench to loosen the rear most nut on the slip clamp shown in Fig.AA. FIG. E 2. Remove the hangers from the grommet supports then remove the entire exhaust system from the vehicle. FIG. AA 3

4 DOWNPIPE/CATALYTIC CONVERTER EXHAUST SYSTEM REMOVAL: REMOVAL (For PN 15201, 15202, 15203, & 15210) 1. Follow steps 1-3 in the Catalytic Converter Back Exhaust System Removal. 2. Remove the V-clamp at the front of the downpipe/catalytic converter with 7/16 socket. Approach clamp from the outside of the frame rail. An air ratchet is recommended to speed up the removal process. (See Fig. F). 3. Now locate the bracket holding the downpipe/catalytic converter hanger. (See Fig. G). Unplug wire connection, (See Fig. H), then use 13 mm wrench to remove the two bolts holding the hanger bracket in place. (See Fig. I & J). Now the hanger bracket and downpipe/catalytic converter can be removed. (See Fig. K & L). NOTE: If your vehicle does not have a catalytic converter, you will not have to disassemble the hanger bracket to remove the downpipe. NOTE: Be sure to keep the rubber isolators as they will be needed for installation of the new exhaust system. If you have any questions about the installation process, call CORSA Performance and ask one of our Sales & Technical Service Representatives. Do not attempt to make any modifications to parts as this will void your warranty. Call (800) FIG. F FIG. G FIG. H FIG. I FIG. J FIG. K FIG. L 4

5 CREW CAB / SHORT BOX INSTALL (For PN & 15205) CORSA Performance Catalytic Converter Back : 1. Remove all exhaust system components from the shipping cartons including clamps. NOTE: There are (3) 4 clamps, (1) gasket ( 01-05) and (4) nuts supplied ( 01-05). INSTALLATION NOTE: Be sure to apply the provided anti-seize lubricant to all bolts, fasteners and clamps. A pouch is included with the hardware kit. Apply the supplied anti-seize lubricant to the threads ONLY of all TORCA band clamps. Failure to follow this procedure can cause the nuts to seize on clamps and potentially damage threads. WARNING: Be sure to thoroughly clean hands after use. Anti-seize lubricant will tarnish stainless steel parts Install Instructions: 2. Locate mid-pipe assembly, gasket and (4) nuts. (See Fig. M). Slide gasket over existing downpipe flange bolts. (See Fig. N). Next, slide the mid-pipe over existing downpipe flange bolts and insert hangers into rubber isolators. (See Fig. O, P & Q). Now use the (4) nuts to snug fit the flange. (See Fig. R). Do not tighten flange nuts at this time. For trucks continue to Step 3 on Page 6. FIG. M FIG. N FIG. O FIG. P Install Instructions: 1. Locate mid-pipe 16DT4023 shown in Fig. MM. Slide the inlet side of the pipe into the factory slip clamp as shown in Fig. NN. 2. Insert the grommet supports through the two hangers as shown in Fig s OO & PP. FIG. Q Tighten the nut at the slip clamp using a 15mm wrench and torque to 45 ft-lbs. Continue to Step 3 on Page 6. FIG. R FIG. MM FIG. NN FIG. OO FIG. PP 5

6 GM Duramax Diesel 3. Locate muffler and slide a supplied 4 TORCA clamp over expanded end and slide muffler inlet into mid-pipe outlet and snug fit clamp. Make sure drain holes in muffler face toward the ground. (See Fig. S & T). Do not tighten clamp at this time. Continue to Step 4 on Page 9. CREW CAB / LONG BOX & CREW CAB/LONG BOX DUALLY INSTALL FIG. T FIG. S (PN 15203, PN 15210, PN 15206, PN 15211) CORSA Performance Catalytic Converter Back : 1. Remove all exhaust system components from the shipping cartons including clamps. NOTE: There are (4) 4 clamps, (1) gasket ( 01-05) and (4) nuts ( 01-05) supplied. INSTALLATION NOTE: Be sure to apply the provided anti-seize lubricant to all bolts, fasteners and clamps. A pouch is included with the hardware kit. Apply the supplied anti-seize lubricant to the threads ONLY of all TORCA band clamps. Failure to follow this procedure can cause the nuts to seize on clamps and potentially damage threads. WARNING: Be sure to thoroughly clean hands after use. Anti-seize lubricant will tarnish stainless steel parts Installation Instructions: 2. Locate mid-pipe assembly, gasket and (4) nuts. (See Fig. GG). Slide gasket over existing downpipe flange bolts. (See Fig. N). Next, slide the mid-pipe over existing downpipe flange bolts and insert hangers into rubber isolators. (See Fig. O, P & HH). Now use the (4) nuts to snug fit the flange. (See Fig. R). Do not tighten flange nuts at this time. For trucks continue to Step 3 on Page 7. FIG. GG FIG. N FIG. O FIG. P If you have any questions about the installation process, call CORSA Performance and ask one of our Sales & Technical Service Representatives. Do not attempt to make any modifications to parts as this will void your warranty. Call (800) FIG. HH FIG. R E - m a i l : s a l e c o r s a p e r f. c o m c o r s a p e r f o r m a n c e. c o m 6

7 GM Duramax Diesel CREW CAB / LONG BOX & CREW CAB/LONG BOX DUALLY INSTALL: Installation Instructions: 1. Locate mid-pipe 16DT4023 shown in Fig. MM. Slide the inlet side of the pipe into the factory slip clamp as shown in Fig. NN. FIG. MM FIG. NN FIG. OO FIG. PP 2. Insert the grommet supports through the two hangers as shown in Fig s OO & PP. Tighten the nut at the slip clamp using a 15mm wrench and torque to 45 ft-lbs. Continue to Step 3 Below. 3. Locate Adapter Pipe Assembly. Slide a supplied 4 TORCA clamp over expanded end and slide adapter pipe inlet into Mid Pipe outlet and snug fit clamp.(see Fig. II, JJ & KK). Do not tighten clamp at this time. 3A. Locate muffler and slide a supplied 4 TORCA clamp over expanded end and slide muffler inlet into Adapter Pipe outlet and snug fit clamp. Make sure drain holes in muffler face toward the ground. (See Fig. S & T). Do not tighten clamp at this time. Continue to Step 4 on Page 9. FIG. II FIG. KK FIG. JJ If you have any questions about the installation process, call CORSA Performance and ask one of our Sales & Technical Service Representatives. Do not attempt to make any modifications to parts as this w i l l v o i d y o u r w a r r a n t y. Call (800) FIG. S FIG. T E - m a i l : s a l e c o r s a p e r f. c o m c o r s a p e r f o r m a n c e. c o m 7

8 EXTENDED CAB / SHORT BOX INSTALL (For PN 15204) CORSA Performance Catalytic Converter Back : 1. Remove all exhaust system components from the shipping cartons including clamps. NOTE: There are (3) 4 clamps, (1) gasket and (4) nuts supplied. INSTALLATION NOTE: Be sure to apply the provided anti-seize lubricant to all bolts, fasteners and clamps. A pouch is included with the hardware kit. Apply the supplied anti-seize lubricant to the threads ONLY of all TORCA band clamps. Failure to follow this procedure can cause the nuts to seize on clamps and potentially damage threads. WARNING: Be sure to thoroughly clean hands after use. Anti-seize lubricant will tarnish stainless steel parts. 2. Locate mid-pipe assembly, gasket and (4) nuts. (See Fig. LL). Slide gasket over existing downpipe flange bolts. (See Fig. N). Next, slide the mid-pipe over existing downpipe flange bolts and insert hangers into rubber isolators. (See Fig. O, MM & Q). Now use the (4) nuts to snug fit the flange. (See Fig. R). Do not tighten flange nuts at this time. 3. Locate muffler and slide a supplied 4 TORCA clamp over expanded end and slide muffler inlet into mid-pipe outlet and snug fit clamp. Make sure drain holes in muffler face toward the ground. (See Fig. S & T). Do not tighten clamp at this time. Continue to Step 4 on Page 9. FIG. LL FIG. N FIG. O FIG. MM FIG. Q FIG. R FIG. S FIG. T 8

9 INSTALLATION CONTINUED. 4. Locate tailpipe assembly and slide a supplied 4 TORCA clamp over expanded end. (See Fig. U). Next, position tailpipe over the axle and slide the expanded end of the tailpipe over the outlet of the muffler, then insert hangers into rubber isolators and snug fit clamp. (See Fig. V, W, X & Y). Do not tighten clamp at this time. 5. Locate Exhaust Tip Assembly and slide the supplied 4 TORCA clamp over notched end. Slide notched end over outlet of tailpipe and snug fit clamp. (See Fig. Z & AA). Do not tighten clamp at this time. 6. Tighten all clamps to TORCA clamp specification (See Fig. BB) making sure there is enough clearance at each hanger and tip is aligned. TORQUE SETTING: 45 ft.-lbs. 7. It is STRONGLY SUGGESTED that all clamps be checked and tightened after road testing the vehicle once the system has cooled. FIG. U FIG. V FIG. W FIG. X FIG. Y FIG. Z FIG. AA TORCA CLAMP FIG. BB Position slot 90 off of bolt Position clamp at end of expanded tube If you have any questions about the installation process, call CORSA Performance and ask one of our Sales & Technical Service Representatives. Do not attempt to make any modifications to parts as this will void your warranty. Call (800)

10 DOWNPIPE INSTALL PN 15202, 15003, Remove all exhaust system components from the shipping cartons including clamps. NOTE: There are (4) lock nuts, (4) washers, (4) bolts, (1) gasket and (1) packet of anti-seize lubricant supplied. INSTALLATION NOTE: Be sure to apply the provided anti-seize lubricant to all bolts, fasteners and clamps. A pouch is included with the hardware kit. Apply the supplied anti-seize lubricant to the threads ONLY of all TORCA band clamps. Failure to follow this procedure can cause the nuts to seize on clamps and potentially damage threads. WARNING: Be sure to thoroughly clean hands after use. Anti-seize lubricant will tarnish stainless steel parts. 2. Locate downpipe assembly and insert downpipe into truck. (See Fig. CC & DD). Use stock V-clamp and snug fit clamp. (See Fig. F). 3. Reassemble stock hanger bracket and wire connection.(see Fig. H, I & J). 4. Locate gasket, lock nuts, washers, bolts and mid pipe. Assemble inlet of mid pipe to outlet of downpipe with gasket, lock nuts, washers and bolts. Snug fit the lock nuts and bolts. Use 3/4 wrench or socket. (See Fig. EE & FF). Insert hangers into rubber isolators. (See Fig. P & Q). 5. Now follow steps 3-7 from the CORSA Performance Catalytic Converter Back Exhaust System Installation (For your particular Part Number) to complete the rest of the installation. FIG. CC FIG. DD NOTE: During cold weather startups, 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. NOTE: Immediately following the installation of your CORSA exhaust 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. EE FIG. FF If you have any questions about the installation process, call CORSA Performance and ask one of our Sales & Technical Service Representatives. Do not attempt to make any modifications to parts as this will void your warranty. Call (800)

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