2008 Chevy Tahoe Buildup - Corsa Performance Cat-Back Exhaust System

Every stock vehicle has power hidden under the plastic beauty cover that is just waiting to be brought out some way. The key is how to unlock that power, and do it safely but without breaking the bank. The quickest and easiest pick-me-up for any truck is an intake and exhaust upgrade. Giving an engine some more breathing room will have a positive effect on both power and mileage. That is exactly what we did to our project '08 Chevy Tahoe.

Out with the stock intake and exhaust, and in with an AEM Brute Force polished intake and a Corsa cat-back exhaust that we picked up from www.autoanything.com. The AEM Brute Force intake features a Dry Flow air filter that doesn't require oil and with the hood popped, it looks show-ready. Providing the rumble, the Corsa exhaust is unlike any other on the market. Using their patented Reflective Sounds Cancelling Technology, the exhaust doesn't have the typical drone while cruising, but once the accelerator is applied, the 5.3L V-8 sounds like it means business. It's the best of both worlds.

We took the Tahoe's performance to a whole new level once we installed an Edge Evolution CTS programmer, also from www.autoanything.com. The Edge programmer really helped reclaim some of the mpg we lost once we bolted on the big lift and wheels and tires we showed you last month. By simply answering some quick questions on the programmer, our Tahoe was back to getting 19 mpg, but with more power than ever before.

To help us install the parts while we snapped the pics, we drove our Tahoe straight to the truck pros at Ekstensive Metalworks, in Houston, Texas. Known for their incredible truck suspensions, Ekstensive also sells truck accessories and can install them on site. We ordered our parts from Autoanything.com, as they have a huge selection of parts that can be searched via truck make and model.

Corsa Performance Cat-Back Exhaust System

The new exhaust kit from Corsa is very simple, but will make a huge difference on our Tahoe in both the way it sounds and performs.
The new exhaust kit from Corsa is very simple, but will make a huge difference on our Taho
A little attitude adjustment was needed, in the form of an impact gun, to remove the factory bolts from the exhaust.
A little attitude adjustment was needed, in the form of an impact gun, to remove the facto
Derrick, of Ekstensive Metalworks in Houston, Texas, is seen here removing the factory muffler.
Derrick, of Ekstensive Metalworks in Houston, Texas, is seen here removing the factory muf

The new exhaust bolts right into the factory location with no fabricating or tweaking needed.
The new exhaust bolts right into the factory location with no fabricating or tweaking need
The 3-inch diameter of the new tubing is much larger and there are fewer bends in the tube so the air can exit quickly and smoothly.
The 3-inch diameter of the new tubing is much larger and there are fewer bends in the tube
With the tubes installed, the much larger Corsa muffler was fitted into place.

A level was used to make sure the new dual tips were straight before they were tack welded into place.
A level was used to make sure the new dual tips were straight before they were tack welded
After everything was said and done, the new exhaust looks and sounds amazing.

AEM Brute Force Cold Air Intake System

Moving to the intake, the factory intake had to be removed before the aftermarket AEM cold air intake could be installed.
Moving to the intake, the factory intake had to be removed before the aftermarket AEM cold
It came free once the MAF sensor was unplugged, a 5/16-inch socket was used to loosen the hose clamps, and the factory airbox pulled free with a 10mm wrench.
It came free once the MAF sensor was unplugged, a 5/16-inch socket was used to loosen the
The new AEM heat shield slips right into the void where the factory airbox was.

The new intake has a bracket to hold up the upper radiator hose so that it isn't just sitting on the metal intake duct, heating the incoming air.
The new intake has a bracket to hold up the upper radiator hose so that it isn't just sitt
After fitting the polished air duct into place, it was attached to the throttle body with the included hose clamps.
After fitting the polished air duct into place, it was attached to the throttle body with
The final step in the install was to install the factory engine plastics and we were done. Now our 5.3L has a fresh supply of cool air to help it breath a little better.
The final step in the install was to install the factory engine plastics and we were done.