Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Exhaust Manifold

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Removal & Installation



4.3L Engines
  1. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, if equipped
     
    Exhaust pipe from the exhaust manifold
     
    Spark plug wires from the plugs and the retaining clips
     
    Heat shields
     

    1. Remove the spark plugs, dipstick tube and wiring, if necessary.
    2.  

  2.  
  3. Unbend the exhaust manifold bolt lock tangs.
  4.  
  5. Remove or disconnect the following:

    Exhaust manifold retaining bolts, washers and tab washers
     
    Exhaust manifold
     
    Old gaskets and discard
     

  6.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Inspect the exhaust manifold for distortion, cracks or damage; replace if necessary.
  4.  
  5. Install or connect the following:

    Exhaust manifold to the cylinder using a new gasket.
     

  6.  
  7. Tighten the exhaust manifold bolts and stud on the first pass to 11 ft. lbs. (5 Nm).
  8.  
  9. Tighten the exhaust manifold bolts and stud on the final pass to 22 ft. lbs.(30 Nm).
    NOTE
    Once the bolts are tightened, bend the tabs on the washers back over the heads of all bolts in order to lock them in position.



    Spark plugs
     
    Dipstick tube
     
    Spark plug wires to the retainer clips and plugs
     
    Exhaust pipe to the manifold
     
    Engine cover (if equipped)
     
    Negative battery cable
     

  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, if equipped
     
    Exhaust Gas Recirculation (EGR) valve, inlet pipe (left side manifold), if necessary
     
    Exhaust pipe from the exhaust manifold
     
    Spark plug wires from the plugs and the retaining clips
     
    Heat shields
     

  4.  
  5. If removing the left side manifold:
    1. Step 1: Remove the power steering/alternator rear bracket, if needed.
    2.  
    3. Step 2: Check for sufficient clearance between the manifold and the intermediate steering shaft. On some models it will be necessary to disconnect the intermediate shaft from the steering gear in order to reposition the shaft for clearance.
    4.  

  6.  
  7. If removing the right side manifold:
    1. Step 1: Remove air conditioning compressor and bracket, then position the assembly aside, if necessary. Do not disconnect the lines or allow them to become kinked or otherwise damaged.
    2.  
    3. Step 2: Remove the spark plugs, dipstick tube and wiring, if necessary
    4.  

  8.  
  9. Unbend the lock tangs.
  10.  
  11. Remove or disconnect the following:

    Exhaust manifold retaining bolts, washers and tab washers
     
    Exhaust manifold
     
    Old gaskets and discard
     

  12.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Inspect the exhaust manifold for distortion, cracks or damage; replace if necessary.
  4.  
  5. Install or connect the following:
    NOTE
    Once the bolts are tightened, bend the tabs on the washers back over the heads of all bolts in order to lock them in position.



    Exhaust manifold to the cylinder using a new gasket. Torque the exhaust manifold-to-cylinder head bolts to 26 ft. lbs. (36 Nm) on the center exhaust tube and to 20 ft. lbs. (28 Nm) on the front and rear exhaust tubes.
     

  6.  
  7. On the right side install:

    Spark plugs
     
    Dipstick tube
     
    Wiring
     
    Air conditioning compressor and bracket assembly, if unbolted
     

  8.  
  9. If the left manifold was removed install:

    Intermediate shaft to the steering gear, if unbolted
     
    Power steering/alternator rear bracket
     
    Air cleaner along with the heat stove pipe and cold air intake pipe
     
    Spark plug wires to the retainer clips and plugs
     
    Exhaust pipe to the manifold
     
    Engine cover, on van models
     
    Negative battery cable
     

  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, if equipped
     
    Exhaust Gas Recirculation (EGR) valve, inlet pipe (left side manifold), if necessary
     
    Exhaust pipe from the exhaust manifold
     
    Spark plug wires from the plugs and the retaining clips
     
    Heat shields
     

  4.  
  5. If removing the left side manifold:
    1. Step 1: Remove the power steering/alternator rear bracket, if needed.
    2.  
    3. Step 2: Check for sufficient clearance between the manifold and the intermediate steering shaft. On some models it will be necessary to disconnect the intermediate shaft from the steering gear in order to reposition the shaft for clearance.
    4.  

  6.  
  7. If removing the right side manifold:
    1. Step 1: Remove air conditioning compressor and bracket, then position the assembly aside, if necessary. Do not disconnect the lines or allow them to become kinked or otherwise damaged.
    2.  
    3. Step 2: Remove the spark plugs, dipstick tube and wiring, if necessary
    4.  

  8.  
  9. Unbend the lock tangs.
  10.  
  11. Remove or disconnect the following:

    Exhaust manifold retaining bolts, washers and tab washers
     
    Exhaust manifold
     
    Old gaskets and discard
     

  12.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Inspect the exhaust manifold for distortion, cracks or damage; replace if necessary.
  4.  
  5. Install or connect the following:
    NOTE
    Once the bolts are tightened, bend the tabs on the washers back over the heads of all bolts in order to lock them in position.



    Exhaust manifold to the cylinder using a new gasket. Torque the exhaust manifold-to-cylinder head bolts to 26 ft. lbs. (36 Nm) on the center exhaust tube and to 20 ft. lbs. (28 Nm) on the front and rear exhaust tubes.
     

  6.  
  7. On the right side install:

    Spark plugs
     
    Dipstick tube
     
    Wiring
     
    Air conditioning compressor and bracket assembly, if unbolted
     

  8.  
  9. If the left manifold was removed install:

    Intermediate shaft to the steering gear, if unbolted
     
    Power steering/alternator rear bracket
     
    Air cleaner along with the heat stove pipe and cold air intake pipe
     
    Spark plug wires to the retainer clips and plugs
     
    Exhaust pipe to the manifold
     
    Engine cover, on van models
     
    Negative battery cable
     

  10.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, if equipped
     
    Exhaust pipe from the exhaust manifold
     
    Spark plug wires from the plugs and the retaining clips
     
    Heat shields
     

    1. Remove the spark plugs, dipstick tube and wiring, if necessary.
    2.  

  2.  
  3. Unbend the exhaust manifold bolt lock tangs.
  4.  
  5. Remove or disconnect the following:

    Exhaust manifold retaining bolts, washers and tab washers
     
    Exhaust manifold
     
    Old gaskets and discard
     

  6.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Inspect the exhaust manifold for distortion, cracks or damage; replace if necessary.
  4.  
  5. Install or connect the following:

    Exhaust manifold to the cylinder using a new gasket.
     

  6.  
  7. Tighten the exhaust manifold bolts and stud on the first pass to 11 ft. lbs. (5 Nm).
  8.  
  9. Tighten the exhaust manifold bolts and stud on the final pass to 22 ft. lbs.(30 Nm).
    NOTE
    Once the bolts are tightened, bend the tabs on the washers back over the heads of all bolts in order to lock them in position.



    Spark plugs
     
    Dipstick tube
     
    Spark plug wires to the retainer clips and plugs
     
    Exhaust pipe to the manifold
     
    Engine cover (if equipped)
     
    Negative battery cable
     

  10.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, if equipped
     
    Exhaust pipe from the exhaust manifold
     
    Spark plug wires from the plugs and the retaining clips
     
    Heat shields
     

    1. Remove the spark plugs, dipstick tube and wiring, if necessary.
    2.  

  2.  
  3. Unbend the exhaust manifold bolt lock tangs.
  4.  
  5. Remove or disconnect the following:

    Exhaust manifold retaining bolts, washers and tab washers
     
    Exhaust manifold
     
    Old gaskets and discard
     

  6.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Inspect the exhaust manifold for distortion, cracks or damage; replace if necessary.
  4.  
  5. Install or connect the following:

    Exhaust manifold to the cylinder using a new gasket.
     

  6.  
  7. Tighten the exhaust manifold bolts and stud on the first pass to 11 ft. lbs. (5 Nm).
  8.  
  9. Tighten the exhaust manifold bolts and stud on the final pass to 22 ft. lbs.(30 Nm).
    NOTE
    Once the bolts are tightened, bend the tabs on the washers back over the heads of all bolts in order to lock them in position.



    Spark plugs
     
    Dipstick tube
     
    Spark plug wires to the retainer clips and plugs
     
    Exhaust pipe to the manifold
     
    Engine cover (if equipped)
     
    Negative battery cable
     

  10.  

4.8L, 5.3L & 6.0L Engines
  1. Remove or disconnect the following:
    NOTE
    Do not remove the spark plug wires from the ignition coils unless required.



    Spark plug wires from the spark plugs
     



    Click image to see an enlarged view

    Fig. Right exhaust manifold removal-4.8L, 5.3L and 6.0L; left side similar



    Exhaust manifold, bolts, and gasket. Discard the gasket.
     
    Heat shield and bolts from the manifold, if required
     

  2.  

To install:


NOTE
Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. A improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.

  1. Clean the exhaust manifold and heat shield in solvent. Dry the exhaust manifold with compressed air.
  2.  
  3. Use a straight edge and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold deck with warpage in excess of 0.01 in. (0.25mm) within the two front or two rear runners or 0.02 in. (0.5mm) overall, may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.
  4.  
  5. Apply a 0.2 in. (5mm) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts.
  6.  
  7. Install the exhaust manifold gasket and exhaust manifold
  8.  
  9. Install the exhaust manifold bolts and tighten, beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
    1. Tighten the exhaust manifold bolts first pass to 11 ft. lbs. (15 Nm).
    2.  
    3. Tighten the exhaust manifold bolts final pass to 18 ft. lbs. (25 Nm). Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.
    4.  

  10.  
  11. Install or connect the following:

    Heat shield and bolts and tighten to 80 inch lbs. (9 Nm) Spark plug wires
     

  12.  

  1. Remove or disconnect the following:
    NOTE
    Do not remove the spark plug wires from the ignition coils unless required.



    Spark plug wires from the spark plugs
     



    Click image to see an enlarged view

    Fig. Right exhaust manifold removal-4.8L, 5.3L and 6.0L; left side similar



    Exhaust manifold, bolts, and gasket. Discard the gasket.
     
    Heat shield and bolts from the manifold, if required
     

  2.  

To install:


NOTE
Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. An improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.

  1. Clean the exhaust manifold and heat shield in solvent. Dry the exhaust manifold with compressed air.
  2.  
  3. Use a straight edge and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold deck with warpage in excess of 0.01 in. (0.25mm) within the two front or two rear runners or 0.02 in. (0.5mm) overall, may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.
  4.  
  5. Apply a 0.2 in. (5mm) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts.
  6.  
  7. Install the exhaust manifold gasket and exhaust manifold
  8.  
  9. Install the exhaust manifold bolts and tighten, beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
    1. Tighten the exhaust manifold bolts first pass to 11 ft. lbs. (15 Nm).
    2.  
    3. Tighten the exhaust manifold bolts final pass to 18 ft. lbs. (25 Nm). Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.
    4.  

  10.  
  11. Install or connect the following:

    Heat shield and bolts and tighten to 80 inch lbs. (9 Nm)
     
    Spark plug wires
     

  12.  

  1. Remove or disconnect the following:
    NOTE
    Do not remove the spark plug wires from the ignition coils unless required.



    Spark plug wires from the spark plugs
     



    Click image to see an enlarged view

    Fig. Right exhaust manifold removal-4.8L, 5.3L and 6.0L; left side similar



    Exhaust manifold, bolts, and gasket. Discard the gasket.
     
    Heat shield and bolts from the manifold, if required
     

  2.  

To install:


NOTE
Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. A improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.

  1. Clean the exhaust manifold and heat shield in solvent. Dry the exhaust manifold with compressed air.
  2.  
  3. Use a straight edge and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold deck with warpage in excess of 0.01 in. (0.25mm) within the two front or two rear runners or 0.02 in. (0.5mm) overall, may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.
  4.  
  5. Apply a 0.2 in. (5mm) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts.
  6.  
  7. Install the exhaust manifold gasket and exhaust manifold
  8.  
  9. Install the exhaust manifold bolts and tighten, beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
    1. Tighten the exhaust manifold bolts first pass to 11 ft. lbs. (15 Nm). Begin with the center 2 bolts, then alternate from side to side working outwards.
    2.  
    3. Tighten the exhaust manifold bolts final pass to 18 ft. lbs. (25 Nm). Begin with the center 2 bolts, then alternate from side to side working outwards. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.
    4.  

  10.  
  11. Install or connect the following:

    Heat shield and bolts and tighten to 80 inch lbs. (9 Nm)
     
    Spark plug wires
     

  12.  

Left Side

NOTE
In order to properly remove the exhaust manifold, remove the AIR components when applicable.

  1. Remove or disconnect the following:


  2.  
  3. AIR center pipe bolt
  4.  
  5. AIR hose clamps and remove the hose assembly
    NOTE
    Do not remove the check valve from the AIR pipe unless service is required.

  6.  
  7. AIR pipe (with check valve), nuts and gasket from the left exhaust manifold
  8.  
  9. AIR pipe studs from the manifold (if required)
  10.  
  11. Spark plug wires from the spark plugs. Do not remove the spark plug wires from the ignition coils unless required.
  12.  
  13. Exhaust manifold, bolts, and gasket. Discard the gasket.
  14.  
  15. Heat shield and bolts from the manifold, if required
    NOTE
    Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. An improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.

  16.  
  17. Clean the exhaust manifold and heat shield in solvent. Dry the exhaust manifold with compressed air. Inspect the exhaust manifold Air Injection Reaction (AIR) passages for restrictions (if applicable). Inspect the AIR flange studs and threaded bolt holes for damage. Inspect the AIR flange gasket surface for excessive scratches or gouging. Inspect the exhaust manifold-to-cylinder head gasket surface for excessive scratches or gouging. Inspect the right side manifold Exhaust Gas Recirculation (EGR) flange sealing surface for excessive scratches or gouging. Inspect the right side manifold EGR flange bolt hole threads for damage. Inspect for a loose or damaged heat shield. Inspect the take down studs for damaged threads.
  18.  
  19. Use a straight edge and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold deck with warpage in excess of 0.25 mm (0.01 in) within the two front or two rear runners or 0.5 mm (0.02 in) overall, may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.
  20.  

To install:


NOTE
Do not apply sealant to the first three threads of the bolt.

  1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts. Install the exhaust manifold and NEW exhaust manifold gasket.
    NOTE
    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.  
  3. Install the exhaust manifold bolts:
    1. Tighten the exhaust manifold bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
    2.  
    3. Tighten the exhaust manifold bolts a final pass to 25 Nm (18 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
    4.  

  4.  
  5. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.
  6.  
  7. Install the heat shield (2) and bolts (3). Tighten the heat shield bolts to 9 Nm (80 inch lbs.).
  8.  
  9. Install the Air Injection Reaction (AIR) pipe studs (if required). Tighten the studs to 5 Nm (45 inch lbs.).
  10.  
  11. Install the AIR pipe (with check valve), NEW gasket and nuts (if required). Tighten the AIR pipe to exhaust manifold nuts to 25 Nm (18 ft. lbs.).
  12.  


NOTE
In order to properly remove the exhaust manifold, remove the AIR components when applicable.

  1. Remove or disconnect the following:


  2.  
  3. AIR center pipe bolt
  4.  
  5. AIR hose clamps and remove the hose assembly
    NOTE
    Do not remove the check valve from the AIR pipe unless service is required.

  6.  
  7. AIR pipe (with check valve), nuts and gasket from the left exhaust manifold
  8.  
  9. AIR pipe studs from the manifold (if required)
  10.  
  11. Spark plug wires from the spark plugs. Do not remove the spark plug wires from the ignition coils unless required.
  12.  
  13. Exhaust manifold, bolts, and gasket. Discard the gasket.
  14.  
  15. Heat shield and bolts from the manifold, if required
    NOTE
    Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. An improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.

  16.  
  17. Clean the exhaust manifold and heat shield in solvent. Dry the exhaust manifold with compressed air. Inspect the exhaust manifold Air Injection Reaction (AIR) passages for restrictions (if applicable). Inspect the AIR flange studs and threaded bolt holes for damage. Inspect the AIR flange gasket surface for excessive scratches or gouging. Inspect the exhaust manifold-to-cylinder head gasket surface for excessive scratches or gouging. Inspect the right side manifold Exhaust Gas Recirculation (EGR) flange sealing surface for excessive scratches or gouging. Inspect the right side manifold EGR flange bolt hole threads for damage. Inspect for a loose or damaged heat shield. Inspect the take down studs for damaged threads.
  18.  
  19. Use a straight edge and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold deck with warpage in excess of 0.25 mm (0.01 in) within the two front or two rear runners or 0.5 mm (0.02 in) overall, may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.
  20.  

To install:


NOTE
Do not apply sealant to the first three threads of the bolt.

  1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts. Install the exhaust manifold and NEW exhaust manifold gasket.
    NOTE
    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.  
  3. Install the exhaust manifold bolts:
    1. Tighten the exhaust manifold bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
    2.  
    3. Tighten the exhaust manifold bolts a final pass to 25 Nm (18 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
    4.  

  4.  
  5. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.
  6.  
  7. Install the heat shield (2) and bolts (3). Tighten the heat shield bolts to 9 Nm (80 inch lbs.).
  8.  
  9. Install the Air Injection Reaction (AIR) pipe studs (if required). Tighten the studs to 5 Nm (45 inch lbs.).
  10.  
  11. Install the AIR pipe (with check valve), NEW gasket and nuts (if required). Tighten the AIR pipe to exhaust manifold nuts to 25 Nm (18 ft. lbs.).
  12.  

Right Side

NOTE
Do not remove the Exhaust Gas Recirculation (EGR) valve from the pipe assembly unless service is required.

  1. Remove or disconnect the following:



    Click image to see an enlarged view

    Fig. EGR valve removal-4.8L, 5.3L, 6.0L


  2.  
  3. EGR valve, gasket, and bolts

    Click image to see an enlarged view

    Fig. EGR pipe removal-4.8L, 5.3L, 6.0L

  4.  
  5. EGR pipe bolt from the intake manifold
  6.  
  7. EGR pipe bolts and gasket from the exhaust manifold
  8.  
  9. EGR pipe bolts from the cylinder head
  10.  
  11. EGR pipe assembly. With mild force, pull the EGR pipe from the intake manifold.
  12.  
  13. O-ring seal from the EGR pipe assembly. Discard the exhaust manifold gasket and O-ring seal.
    NOTE
    In order to properly remove the exhaust manifold, remove the AIR components when applicable. Do not remove the check valve from the Air Injection Reaction (AIR) pipe unless service is required.

  14.  
  15. AIR pipe (with check valve), nuts and gasket from the right exhaust manifold.

    AIR pipe studs from the manifold (if required)
     

  16.  
  17. Spark plug wires from the spark plugs. Do not remove the spark plug wires from the ignition coils unless required.

    Click image to see an enlarged view

    Fig. Right exhaust manifold removal-4.8L, 5.3L, 6.0L

  18.  
  19. Exhaust manifold, bolts, and gasket. Discard the gasket.
  20.  
  21. Heat shield and bolts from the manifold, if required
  22.  

To install:


NOTE
Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. A improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.

  1. Clean the exhaust manifold and heat shield in solvent. Dry the exhaust manifold with compressed air. Inspect the exhaust manifold Air Injection Reaction (AIR) passages for restrictions (if applicable). Inspect the AIR flange studs and threaded bolt holes for damage. Inspect the AIR flange gasket surface for excessive scratches or gouging. Inspect the exhaust manifold-to-cylinder head gasket surface for excessive scratches or gouging. Inspect the right side manifold Exhaust Gas Recirculation (EGR) flange sealing surface for excessive scratches or gouging. Inspect the right side manifold EGR flange bolt hole threads for damage. Inspect for a loose or damaged heat shield (2). Inspect the take down studs for damaged threads.
  2.  
  3. Use a straight edge and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold deck with warpage in excess of 0.25 mm (0.01 in) within the two front or two rear runners or 0.5 mm (0.02 in) overall, may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.
    NOTE
    Do not reuse Exhaust Gas Recirculation (EGR) valve and pipe gaskets or seals during assembly. Install NEW gaskets and O-ring seal.

  4.  
  5. Install or connect the following:


  6.  
  7. A 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts.
    NOTE
    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.



    Exhaust manifold gasket and exhaust manifold
     

  8.  
  9. Install the exhaust manifold bolts:
    1. Tighten the exhaust manifold bolts first pass to 15 Nm (11 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
    2.  
    3. Tighten the exhaust manifold bolts final pass to 30 Nm (22 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.
    4.  

  10.  
  11. Install or connect the following:


  12.  
  13. Heat shield and bolts. Tighten the heat shield bolts to 9 Nm (80 inch lbs.).
  14.  
  15. AIR pipe studs (if required). Tighten the studs to 5 Nm (45 inch lbs.).
  16.  
  17. AIR pipe (with check valve), NEW gasket and nuts (if required). Tighten the AIR pipe to exhaust manifold nuts to 25 Nm (18 ft. lbs.).
  18.  
  19. AIR hose assembly and clamps.
  20.  
  21. AIR pipe bracket-to-cylinder head bolt. Tighten the AIR pipe bracket bolt to 50 Nm (37 ft. lbs.).
  22.  
  23. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR pipe. Insert the EGR pipe into the intake manifold.
  24.  
  25. Start the EGR pipe to intake manifold bolt (1). Do not tighten the bolt at this time. Install the EGR pipe to cylinder head bolts. Do not tighten the bolts at this time.
  26.  
  27. Install a NEW EGR pipe exhaust manifold gasket and bolts:
    1. Tighten the EGR pipe to intake manifold bolt to 10 Nm (89 inch lbs.).
    2.  
    3. Tighten the EGR pipe to cylinder head bolts to 50 Nm (37 ft. lbs.).
    4.  
    5. Tighten the EGR pipe to exhaust manifold bolts to 30 Nm (22 ft. lbs.).
    6.  

  28.  
  29. Install the EGR valve, a NEW gasket, and bolts. Tighten the EGR valve bolts a first pass to 10 Nm (89 inch lbs.). Tighten the EGR valve bolts a second pass to 25 Nm (18 ft. lbs.).
  30.  


NOTE
Do not remove the Exhaust Gas Recirculation (EGR) valve from the pipe assembly unless service is required.

  1. Remove or disconnect the following:



    Click image to see an enlarged view

    Fig. EGR valve removal-4.8L, 5.3L, 6.0L


  2.  
  3. EGR valve, gasket, and bolts

    Click image to see an enlarged view

    Fig. EGR pipe removal-4.8L, 5.3L, 6.0L

  4.  
  5. EGR pipe bolt from the intake manifold
  6.  
  7. EGR pipe bolts and gasket from the exhaust manifold
  8.  
  9. EGR pipe bolts from the cylinder head
  10.  
  11. EGR pipe assembly. With mild force, pull the EGR pipe from the intake manifold.
  12.  
  13. O-ring seal from the EGR pipe assembly. Discard the exhaust manifold gasket and O-ring seal.
    NOTE
    In order to properly remove the exhaust manifold, remove the AIR components when applicable. Do not remove the check valve from the Air Injection Reaction (AIR) pipe unless service is required.

  14.  
  15. AIR pipe (with check valve), nuts and gasket from the right exhaust manifold.

    AIR pipe studs from the manifold (if required)
     

  16.  
  17. Spark plug wires from the spark plugs. Do not remove the spark plug wires from the ignition coils unless required.

    Click image to see an enlarged view

    Fig. Right exhaust manifold removal-4.8L, 5.3L, 6.0L

  18.  
  19. Exhaust manifold, bolts, and gasket. Discard the gasket.
  20.  
  21. Heat shield and bolts from the manifold, if required
  22.  

To install:


NOTE
Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. A improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.

  1. Clean the exhaust manifold and heat shield in solvent. Dry the exhaust manifold with compressed air. Inspect the exhaust manifold Air Injection Reaction (AIR) passages for restrictions (if applicable). Inspect the AIR flange studs and threaded bolt holes for damage. Inspect the AIR flange gasket surface for excessive scratches or gouging. Inspect the exhaust manifold-to-cylinder head gasket surface for excessive scratches or gouging. Inspect the right side manifold Exhaust Gas Recirculation (EGR) flange sealing surface for excessive scratches or gouging. Inspect the right side manifold EGR flange bolt hole threads for damage. Inspect for a loose or damaged heat shield (2). Inspect the take down studs for damaged threads.
  2.  
  3. Use a straight edge and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold deck with warpage in excess of 0.25 mm (0.01 in) within the two front or two rear runners or 0.5 mm (0.02 in) overall, may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.
    NOTE
    Do not reuse Exhaust Gas Recirculation (EGR) valve and pipe gaskets or seals during assembly. Install NEW gaskets and O-ring seal.

  4.  
  5. Install or connect the following:


  6.  
  7. A 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts.
    NOTE
    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.



    Exhaust manifold gasket and exhaust manifold
     

  8.  
  9. Install the exhaust manifold bolts:
    1. Tighten the exhaust manifold bolts first pass to 15 Nm (11 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
    2.  
    3. Tighten the exhaust manifold bolts final pass to 30 Nm (22 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.
    4.  

  10.  
  11. Install or connect the following:


  12.  
  13. Heat shield and bolts. Tighten the heat shield bolts to 9 Nm (80 inch lbs.).
  14.  
  15. AIR pipe studs (if required). Tighten the studs to 5 Nm (45 inch lbs.).
  16.  
  17. AIR pipe (with check valve), NEW gasket and nuts (if required). Tighten the AIR pipe to exhaust manifold nuts to 25 Nm (18 ft. lbs.).
  18.  
  19. AIR hose assembly and clamps.
  20.  
  21. AIR pipe bracket-to-cylinder head bolt. Tighten the AIR pipe bracket bolt to 50 Nm (37 ft. lbs.).
  22.  
  23. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR pipe. Insert the EGR pipe into the intake manifold.
  24.  
  25. Start the EGR pipe to intake manifold bolt (1). Do not tighten the bolt at this time. Install the EGR pipe to cylinder head bolts. Do not tighten the bolts at this time.
  26.  
  27. Install a NEW EGR pipe exhaust manifold gasket and bolts:
    1. Tighten the EGR pipe to intake manifold bolt to 10 Nm (89 inch lbs.).
    2.  
    3. Tighten the EGR pipe to cylinder head bolts to 50 Nm (37 ft. lbs.).
    4.  
    5. Tighten the EGR pipe to exhaust manifold bolts to 30 Nm (22 ft. lbs.).
    6.  

  28.  
  29. Install the EGR valve, a NEW gasket, and bolts. Tighten the EGR valve bolts a first pass to 10 Nm (89 inch lbs.). Tighten the EGR valve bolts a second pass to 25 Nm (18 ft. lbs.).
  30.  

4.8L, 5.3L, 6.0L & 6.2L Engines
  1. Remove or disconnect the following:
    NOTE
    Do not remove the spark plug wires from the ignition coils unless required.



    Spark plug wires from the spark plugs
     



    Click image to see an enlarged view

    Fig. Right exhaust manifold removal-4.8L, 5.3L, 6.0L and 6.2L; left side similar



    Exhaust manifold, bolts, and gasket. Discard the gasket.
     
    Heat shield and bolts from the manifold, if required
     

  2.  

To install:


NOTE
Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. A improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.

  1. Clean the exhaust manifold and heat shield in solvent. Dry the exhaust manifold with compressed air.
  2.  
  3. Use a straight edge and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold deck with warpage in excess of 0.01 in. (0.25mm) within the two front or two rear runners or 0.02 in. (0.5mm) overall, may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.
  4.  
  5. Apply a 0.2 in. (5mm) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts.
  6.  
  7. Install the exhaust manifold gasket and exhaust manifold
  8.  
  9. Install the exhaust manifold bolts and tighten, beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
    1. Tighten the exhaust manifold bolts first pass to 11 ft. lbs. (15 Nm). Begin with the center 2 bolts, then alternate from side to side working outwards.
    2.  
    3. Tighten the exhaust manifold bolts final pass to 18 ft. lbs. (25 Nm). Begin with the center 2 bolts, then alternate from side to side working outwards. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.
    4.  

  10.  
  11. Install or connect the following:

    Heat shield and bolts and tighten to 80 inch lbs. (9 Nm)
     
    Spark plug wires
     

  12.  

5.0L And 5.7L Engines
  1. Remove or disconnect the following:
    NOTE
    On models with air conditioning, it may be necessary to remove the compressor, do not disconnect the compressor lines.



    Negative battery cable
     
    Engine cover
     
    Air cleaner, if needed
     
    Exhaust pipe at the manifold
     
    Oxygen Sensor (O 2 S) wiring, if equipped
     
    AIR hose at the check valve
     
    Exhaust Gas Recirculation (EGR) valve, inlet pipe
     
    Heat stove pipe and the dipstick tube bracket, if working on the right side of the engine
     
    Power steering pump rear bracket at the manifold, if removing the left side manifold
     
    Loosen the alternator and remove the lower bracket, if necessary
     
    Air conditioner compressor rear bracket and the diverter valve and bracket. if needed
     



    Manifold bolts and the manifold(s) Some models have lock tabs on the front and rear manifold bolts which must be removed before removing the bolts.

    Click image to see an enlarged view

    Fig. Exploded view of the left exhaust manifold, the right side is similar-5.0L and 5.7L engines

     

  2.  

To install:

  1. Clean gasket surfaces, and inspect manifold for cracks replace as necessary.
  2.  
  3. Install the manifold and torque it in the following steps:
    1. Step 1: 15 ft. lbs. (20 Nm).
    2.  
    3. Step 2: 22 ft. lbs. (30 Nm).
    4.  

  4.  
  5. Install or connect the following:

    Alternator, if removed
     
    Air conditioning compressor, if removed
     
    Diverter, if removed
     
    Power steering brackets, if removed
     
    Dipstick tube on right side
     
    EGR inlet pipe
     
    Oxygen sensor connector, if equipped
     
    Exhaust pipes
     
    Negative battery cable
     

  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    On models with air conditioning, it may be necessary to remove the compressor, do not disconnect the compressor lines.



    Negative battery cable
     
    Engine cover
     
    Air cleaner, if needed
     
    Exhaust pipe at the manifold
     
    Oxygen (O 2 S) sensor wiring, if equipped
     
    AIR hose at the check valve
     
    Exhaust Gas Recirculation (EGR) valve, inlet pipe
     
    Heat stove pipe and the dipstick tube bracket, if working on the right side of the engine
     
    Power steering pump rear bracket at the manifold, if removing the left side manifold
     
    Loosen the alternator and remove the lower bracket, if necessary
     
    Air conditioner compressor rear bracket and the diverter valve and bracket. if needed
     



    Manifold bolts and the manifold(s) Some models have lock tabs on the front and rear manifold bolts which must be removed before removing the bolts.
     

  4.  

To install:

  1. Clean gasket surfaces, and inspect manifold for cracks replace as necessary.
  2.  
  3. Install manifold and torque it in 2 steps.
    1. Step 1: Torque the bolts to 15 ft. lbs. (20 Nm)
    2.  
    3. Step 2: Torque the bolts to 22 ft. lbs. (30 Nm)
    4.  

  4.  
  5. Install or connect the following:

    Alternator, if removed
     
    Air conditioning compressor, if removed
     
    Diverter, if removed
     
    Power steering brackets, if removed
     
    Dipstick tube on right side
     
    EGR inlet pipe
     
    Oxygen sensor connector, if equipped
     
    Exhaust pipes
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the left exhaust manifold, the right side is similar-5.0L and 5.7L engines

     

  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    On models with air conditioning, it may be necessary to remove the compressor, do not disconnect the compressor lines.



    Negative battery cable
     
    Engine cover
     
    Air cleaner, if needed
     
    Exhaust pipe at the manifold
     
    Oxygen (O 2 S) sensor wiring, if equipped
     
    AIR hose at the check valve
     
    Exhaust Gas Recirculation (EGR) valve, inlet pipe
     
    Heat stove pipe and the dipstick tube bracket, if working on the right side of the engine
     
    Power steering pump rear bracket at the manifold, if removing the left side manifold
     
    Loosen the alternator and remove the lower bracket, if necessary
     
    Air conditioner compressor rear bracket and the diverter valve and bracket. if needed
     



    Manifold bolts and the manifold(s) Some models have lock tabs on the front and rear manifold bolts which must be removed before removing the bolts.
     

  4.  

To install:

  1. Clean gasket surfaces, and inspect manifold for cracks replace as necessary.
  2.  
  3. Install manifold and torque it in 2 steps.
    1. Step 1: Torque the bolts to 15 ft. lbs. (20 Nm)
    2.  
    3. Step 2: Torque the bolts to 22 ft. lbs. (30 Nm)
    4.  

  4.  
  5. Install or connect the following:

    Alternator, if removed
     
    Air conditioning compressor, if removed
     
    Diverter, if removed
     
    Power steering brackets, if removed
     
    Dipstick tube on right side
     
    EGR inlet pipe
     
    Oxygen sensor connector, if equipped
     
    Exhaust pipes
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the left exhaust manifold, the right side is similar-5.0L and 5.7L engines

     

  6.  

5.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    On models with air conditioning, it may be necessary to remove the compressor, do not disconnect the compressor lines.



    Negative battery cable
     
    Engine cover
     
    Air cleaner, if needed
     
    Exhaust pipe at the manifold
     
    Oxygen Sensor (O 2 S) wiring, if equipped
     
    AIR hose at the check valve
     
    Exhaust Gas Recirculation (EGR) valve, inlet pipe
     
    Heat stove pipe and the dipstick tube bracket, if working on the right side of the engine
     
    Power steering pump rear bracket at the manifold, if removing the left side manifold
     
    Loosen the alternator and remove the lower bracket, if necessary
     
    Air conditioner compressor rear bracket and the diverter valve and bracket. if needed
     



    Manifold bolts and the manifold(s) Some models have lock tabs on the front and rear manifold bolts which must be removed before removing the bolts.
     

  4.  

To install:

  1. Clean gasket surfaces, and inspect manifold for cracks replace as necessary.
  2.  
  3. Install the manifold, then torque the bolts in 2 steps, as follows:
    1. Step 1: Torque to 15 ft. lbs. (20 Nm).
    2.  
    3. Step 2: Torque to 22 ft. lbs. (30 Nm).
    4.  

  4.  
  5. Install or connect the following:

    Alternator, if removed
     
    Air conditioning compressor, if removed
     
    Diverter, if removed
     
    Power steering brackets, if removed
     
    Dipstick tube on right side
     
    EGR inlet pipe
     
    Oxygen sensor connector, if equipped
     
    Exhaust pipes
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the left exhaust manifold, the right side is similar-5.7L engines

     

  6.  

6.5L Engine
  1. Remove or disconnect the following:

    Batteries cables
     
    Exhaust pipe from the manifold flange
     
    Engine oil and transmission oil fill tubes
     
    Engine cover and disconnect the glow plug wires
     
    Glow plugs
     
    Turbocharger assembly, as required
     
    Air conditioner compressor rear bracket, as required
     
    Manifold bolts and the manifold
     

  2.  

To install:

  1. Install or connect the following:

    Exhaust manifold. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Exhaust pipe
     
    Glow plugs and electrical connection
     
    Engine and transmission oil fill tubes
     
    Air conditioning compressor bracket
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the left exhaust manifold mounting-6.5L diesel engines



    Click image to see an enlarged view

    Fig. Exploded view of the right exhaust manifold mounting-6.5L diesel engines

     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Batteries cables
     
    Exhaust pipe from the manifold flange
     
    Engine oil and transmission oil fill tubes
     
    Engine cover and disconnect the glow plug wires
     
    Glow plugs
     
    Turbocharger assembly, as required
     
    Air conditioner compressor rear bracket, as required
     
    Manifold bolts and the manifold

    Click image to see an enlarged view

    Fig. Exploded view of the left exhaust manifold mounting-6.5L diesel engines



    Click image to see an enlarged view

    Fig. Exploded view of the right exhaust manifold mounting-6.5L diesel engines

     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Exhaust pipe
     
    Glow plugs and electrical connection
     
    Engine and transmission oil fill tubes
     
    Air conditioning compressor bracket
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Batteries cables
     
    Exhaust pipe from the manifold flange
     
    Engine oil and transmission oil fill tubes
     
    Engine cover and disconnect the glow plug wires
     
    Glow plugs
     
    Turbocharger assembly, as required
     
    Air conditioner compressor rear bracket, as required
     
    Manifold bolts and the manifold
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold. Torque the bolts to 26 ft. lbs. (35 Nm)
     
    Exhaust pipe
     
    Glow plugs and electrical connection
     
    Engine and transmission oil fill tubes
     
    Air conditioning compressor bracket
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the left exhaust manifold mounting-6.5L diesel engines



    Click image to see an enlarged view

    Fig. Exploded view of the right exhaust manifold mounting-6.5L diesel engines

     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Batteries cables
     
    Exhaust pipe from the manifold flange
     
    Engine oil and transmission oil fill tubes
     
    Engine cover and disconnect the glow plug wires
     
    Glow plugs
     
    Turbocharger assembly, as required
     
    Air conditioner compressor rear bracket, as required
     
    Manifold bolts and the manifold
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold. Torque the bolts to 26 ft. lbs. (35 Nm)
     
    Exhaust pipe
     
    Glow plugs and electrical connection
     
    Engine and transmission oil fill tubes
     
    Air conditioning compressor bracket
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the left exhaust manifold mounting-6.5L diesel engines



    Click image to see an enlarged view

    Fig. Exploded view of the right exhaust manifold mounting-6.5L diesel engines

     

  2.  

6.6L Engine
Left Side
  1. Raise the vehicle.
  2.  
  3. Remove or disconnect the following:

    Bolts securing the left exhaust pipe heat shield and move the heat shield aside
     
    Left exhaust pipe-to-manifold bolts
     
    Left front wheel
     
    Left front fender splash shield
     
    Charge air cooler duct
     
    Exhaust manifold heat shield bolts and shield
     
    2 nuts and 6 bolts with the plain washer and bell view washer from the left manifold
     
    Exhaust manifold by removing it from the rear, then the front studs and sliding it out the bottom, past the oil filter
     
    Exhaust manifold gasket and discard
     

  4.  

To install:

  1. Installation is the reverse of the removal procedure. Tighten the retainers as follows:
    1. Exhaust manifold nuts and bolts, in sequence, in 2 passes to 25 ft. lbs. (34 Nm).

      Click image to see an enlarged view

      Fig. Left and right side exhaust manifold bolt removal and installation sequence-6.6L engine

    2.  
    3. Heat shield bolts: 71 inch lbs. (8 Nm).
    4.  
    5. Exhaust pipe-to-manifold bolts: 39 ft. lbs. (59 Nm).
    6.  

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Raise the vehicle.
  4.  
  5. Remove or disconnect the following:

    Bolts securing the left exhaust pipe heat shield. Move the heat shield aside for access to the exhaust pipe-to-manifold bolts
     
    Left exhaust pipe-to-manifold bolts
     
    Left front wheel
     
    Left front fender splash shield
     
    Charge air cooler duct
     
    Exhaust manifold heat shield bolts and shield
     
    2 nuts and 6 bolts with the plain washer and bell view washer from the left manifold
     
    Exhaust manifold by removing it from the rear, then the front studs and sliding it out the bottom, past the oil filter
     
    Exhaust manifold gasket and discard
     

  6.  
  7. Installation is the reverse of the removal procedure. Tighten the retainers as follows:

    Exhaust manifold nuts and bolts, in sequence, in 2 passes: 25 ft. lbs. (34 Nm)

    Click image to see an enlarged view

    Fig. Left and right side exhaust manifold bolt torque sequence-6.6L engine

     
    Heat shield bolts: 71 inch lbs. (8 Nm)
     
    Exhaust pipe-to-manifold bolts: 39 ft. lbs. (59 Nm)
     

  8.  

  1. Raise the vehicle.
  2.  
  3. Remove or disconnect the following:

    Bolts securing the left exhaust pipe heat shield and move the heat shield aside
     
    Left exhaust pipe-to-manifold bolts
     
    Left front wheel
     
    Left front fender splash shield
     
    Charge air cooler duct
     
    Exhaust manifold heat shield bolts and shield
     
    2 nuts and 6 bolts with the plain washer and bell view washer from the left manifold
     
    Exhaust manifold by removing it from the rear, then the front studs and sliding it out the bottom, past the oil filter
     
    Exhaust manifold gasket and discard
     

  4.  

To install:

  1. Installation is the reverse of the removal procedure. Tighten the retainers as follows:
    1. Exhaust manifold nuts and bolts, in sequence, in 2 passes to 25 ft. lbs. (34 Nm).

      Click image to see an enlarged view

      Fig. Left and right side exhaust manifold bolt removal and installation sequence-6.6L engines

    2.  
    3. Heat shield bolts: 71 inch lbs. (8 Nm).
    4.  
    5. Exhaust pipe-to-manifold bolts: 39 ft. lbs. (59 Nm).
    6.  

  2.  

  1. Raise the vehicle.
  2.  
  3. Remove or disconnect the following:

    Bolts securing the left exhaust pipe heat shield and move the heat shield aside
     
    Left exhaust pipe-to-manifold bolts
     
    Left front wheel
     
    Left front fender splash shield
     
    Charge air cooler duct
     
    Exhaust manifold heat shield bolts and shield
     
    2 nuts and 6 bolts with the plain washer and bell view washer from the left manifold
     
    Exhaust manifold by removing it from the rear, then the front studs and sliding it out the bottom, past the oil filter
     
    Exhaust manifold gasket and discard
     

  4.  

To install:

  1. Installation is the reverse of the removal procedure. Tighten the retainers as follows:
    1. Exhaust manifold nuts and bolts, in sequence, in 2 passes to 25 ft. lbs. (34 Nm).

      Click image to see an enlarged view

      Fig. Left and right side exhaust manifold bolt removal and installation sequence-6.6L engines

    2.  
    3. Heat shield bolts: 71 inch lbs. (8 Nm).
    4.  
    5. Exhaust pipe-to-manifold bolts: 39 ft. lbs. (59 Nm).
    6.  

  2.  

Right Side
  1. Raise the vehicle.
  2.  
  3. Remove or disconnect the following:

    Right front wheel
     
    Right front fender splash shield
     
    Exhaust manifold heat shield bolts and shield
     
    Right exhaust pipe-to-manifold bolts
     
    2 nuts and 6 bolts with the plain washer and bell view washer from the left manifold
     
    Exhaust manifold by removing it from the rear, then the front studs and sliding it out the bottom, past the oil filter
     
    Bolt for the oil level dipstick tube, to remove the gasket
     
    Exhaust manifold gasket and discard
     

  4.  

To install:

  1. Installation is the reverse of the removal procedure. Tighten the retainers as follows:
    1. Oil level dipstick tube: 15 ft. lbs. (20 Nm).
    2.  
    3. Exhaust manifold nuts and bolts, in sequence, in 2 passes: 25 ft. lbs. (34 Nm).
    4.  
    5. Heat shield bolts: 71 inch lbs. (8 Nm).
    6.  
    7. Exhaust pipe-to-manifold bolts: 39 ft. lbs. (59 Nm).
    8.  

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Raise the vehicle.
  4.  
  5. Remove or disconnect the following:

    Right front wheel
     
    Right front fender splash shield
     
    Exhaust manifold heat shield bolts and shield
     
    Right exhaust pipe-to-manifold bolts
     
    2 nuts and 6 bolts with the plain washer and bell view washer from the left manifold
     
    Exhaust manifold by removing it from the rear, then the front studs and sliding it out the bottom, past the oil filter
     
    Bolt for the oil level dipstick tube, to remove the gasket
     
    Exhaust manifold gasket and discard
     

  6.  
  7. Installation is the reverse of the removal procedure. Tighten the retainers as follows:

    Oil level dipstick tube: 15 ft. lbs. (20 Nm)
     
    Exhaust manifold nuts and bolts, in sequence, in 2 passes: 25 ft. lbs. (34 Nm)
     
    Heat shield bolts: 71 inch lbs. (8 Nm)
     
    Exhaust pipe-to-manifold bolts: 39 ft. lbs. (59 Nm)
     

  8.  

  1. Raise the vehicle.
  2.  
  3. Remove or disconnect the following:

    Right front wheel
     
    Right front fender splash shield
     
    Exhaust manifold heat shield bolts and shield
     
    Right exhaust pipe-to-manifold bolts
     
    2 nuts and 6 bolts with the plain washer and bell view washer from the left manifold
     
    Exhaust manifold by removing it from the rear, then the front studs and sliding it out the bottom, past the oil filter
     
    Bolt for the oil level dipstick tube, to remove the gasket
     
    Exhaust manifold gasket and discard
     

  4.  

To install:

  1. Installation is the reverse of the removal procedure. Tighten the retainers as follows:
    1. Oil level dipstick tube: 15 ft. lbs. (20 Nm).
    2.  
    3. Exhaust manifold nuts and bolts, in sequence, in 2 passes: 25 ft. lbs. (34 Nm).
    4.  
    5. Heat shield bolts: 71 inch lbs. (8 Nm).
    6.  
    7. Exhaust pipe-to-manifold bolts: 39 ft. lbs. (59 Nm).
    8.  

  2.  

  1. Raise the vehicle.
  2.  
  3. Remove or disconnect the following:

    Right front wheel
     
    Right front fender splash shield
     
    Exhaust manifold heat shield bolts and shield
     
    Right exhaust pipe-to-manifold bolts
     
    2 nuts and 6 bolts with the plain washer and bell view washer from the left manifold
     
    Exhaust manifold by removing it from the rear, then the front studs and sliding it out the bottom, past the oil filter
     
    Bolt for the oil level dipstick tube, to remove the gasket
     
    Exhaust manifold gasket and discard
     

  4.  

To install:

  1. Installation is the reverse of the removal procedure. Tighten the retainers as follows:
    1. Oil level dipstick tube: 15 ft. lbs. (20 Nm).
    2.  
    3. Exhaust manifold nuts and bolts, in sequence, in 2 passes: 25 ft. lbs. (34 Nm).
    4.  
    5. Heat shield bolts: 71 inch lbs. (8 Nm).
    6.  
    7. Exhaust pipe-to-manifold bolts: 39 ft. lbs. (59 Nm).
    8.  

  2.  

7.4L Engines
  1. Remove or disconnect the following:
    NOTE
    Leave the front nut (left manifold) or rear nut (right manifold) in place for support.



    Negative battery cable
     
    Engine cover (if equipped)
     
    Heat stove pipe and the dipstick tube, if removing the right side manifold
     
    Exhaust Gas Recirculation (EGR) valve inlet pipe
     
    Oxygen Sensor (O 2 S) wiring, if equipped
     
    AIR hose at the check valve, if applicable
     
    Spark plugs and wires
     
    Exhaust manifold bolts and the spark plug heat shields
     



    Heat shield bolts from the engine mount and bell housing
     
    Heat shield, if equipped
     
    Exhaust pipe at the manifold
     



    Exhaust manifold
     

  2.  

To install:

  1. Clean the mating surfaces and the retainer threads.
  2.  
  3. Install or connect the following:

    Manifold, spark plug heat shields and nuts. Torque the nuts to 22 ft. lbs. (30 Nm), starting from the center bolts and working towards the outside.
     
    Exhaust pipe
     
    Spark plugs and wires
     
    AIR hose at check valve, if removed
     
    O 2 S connector, if equipped
     
    EGR pipe and dipstick tube
     
    Negative battery cable
     

  4.  
  5. Run engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Leave the front nut (left manifold) or rear nut (right manifold) in place for support.



    Negative battery cable
     
    Heat stove pipe and the dipstick tube, if removing the right side manifold
     
    Exhaust Gas Recirculation (EGR) valve inlet pipe
     
    Oxygen Sensor (O 2 S) wiring, if equipped
     
    AIR hose at the check valve, if applicable
     
    Spark plugs and wires
     
    Exhaust manifold bolts and the spark plug heat shields
     



    Heat shield bolts from the engine mount and bell housing
     
    Heat shield, if equipped
     
    Exhaust pipe at the manifold
     
    Exhaust manifold
     

  4.  

To install:

  1. Clean the mating surfaces and the retainer threads.
  2.  
  3. Install or connect the following:

    Manifold, spark plug heat shields and nuts. Torque the nuts to 22 ft. lbs. (30 Nm), starting from the center bolts and working outside.
     
    Exhaust pipe
     
    Spark plugs and wires
     
    AIR hose at check valve, if removed
     
    O 2 S connector, if equipped
     
    EGR pipe and dipstick tube
     
    Negative battery cable
     

  4.  
  5. Run engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Leave the front nut (left manifold) or rear nut (right manifold) in place for support.



    Negative battery cable
     
    Engine cover, on van models
     
    Heat stove pipe and the dipstick tube. If removing the right side manifold
     
    Exhaust Gas Recirculation (EGR) valve inlet pipe
     
    Oxygen (O 2 S) sensor wiring, if equipped
     
    AIR hose at the check valve, if applicable
     
    Spark plugs and wires
     
    Exhaust manifold bolts and the spark plug heat shields
     



    Heat shield bolts from the engine mount and bell housing
     
    Heat shield, if equipped
     
    Exhaust pipe at the manifold
     



    Exhaust manifold
     

  4.  

To install:

  1. Clean the mating surfaces and the retainer threads.
  2.  
  3. Install or connect the following:

    Manifold, spark plug heat shields and nuts. Torque the nuts to 22 ft. lbs. (30 Nm), starting from the center bolts and working towards the outside.
     
    Exhaust pipe
     
    Spark plugs and wires
     
    AIR hose at check valve, if removed
     
    Oxygen sensor connector, if equipped
     
    EGR pipe and dipstick tube
     
    Negative battery cable
     

  4.  
  5. Run engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Leave the front nut (left manifold) or rear nut (right manifold) in place for support.



    Negative battery cable
     
    Engine cover, on van models
     
    Heat stove pipe and the dipstick tube. If removing the right side manifold
     
    Exhaust Gas Recirculation (EGR) valve inlet pipe
     
    Oxygen (O 2 S) sensor wiring, if equipped
     
    AIR hose at the check valve, if applicable
     
    Spark plugs and wires
     
    Exhaust manifold bolts and the spark plug heat shields
     



    Heat shield bolts from the engine mount and bell housing
     
    Heat shield, if equipped
     
    Exhaust pipe at the manifold
     



    Exhaust manifold
     

  4.  

To install:

  1. Clean the mating surfaces and the retainer threads.
  2.  
  3. Install or connect the following:

    Manifold, spark plug heat shields and nuts. Torque the nuts to 22 ft. lbs. (30 Nm), starting from the center bolts and working towards the outside.
     
    Exhaust pipe
     
    Spark plugs and wires
     
    AIR hose at check valve, if removed
     
    Oxygen sensor connector, if equipped
     
    EGR pipe and dipstick tube
     
    Negative battery cable
     

  4.  
  5. Run engine and check for leaks.
  6.  

8.1L Engines
  1. Remove or disconnect the following:

    Spark plug wires
     
    Spark plugs
     
    Exhaust manifold heat shield bolts and shield
     
    Exhaust manifold bolt and nuts
     
    Exhaust manifold
     
    Exhaust manifold gasket and discard
     

  2.  

To install:

  1. Clean the mating surfaces and the retainer threads.
  2.  
  3. Install or connect the following:

    New exhaust manifold gasket
     
    Exhaust manifold
     
    Exhaust manifold bolt and nuts. Tighten the bolt to 26 ft. lbs. (35 Nm) and the nuts to 12 ft. lbs. (16 Nm).
     
    If removed, tighten the studs to 15 ft. lbs. (20 Nm).
     
    Heat shield. Tighten the retaining bolts and nuts to 18 ft. lbs. (25 Nm).
     
    Spark plugs and plug wires
     

  4.  

  1. Remove or disconnect the following:

    Spark plug wires
     
    Spark plugs
     
    Exhaust manifold heat shield bolts and shield
     
    Exhaust manifold bolt and nuts
     
    Exhaust manifold
     
    Exhaust manifold gasket and discard
     

  2.  

To install:

  1. Clean the mating surfaces and the retainer threads.
  2.  
  3. Install or connect the following:

    New exhaust manifold gasket
     
    Exhaust manifold
     
    Exhaust manifold bolt and nuts. Tighten the bolt to 26 ft. lbs. (35 Nm) and the nuts to 12 ft. lbs. (16 Nm).
     
    If removed, tighten the studs to 15 ft. lbs. (20 Nm).
     
    Heat shield. Tighten the retaining bolts and nuts to 18 ft. lbs. (25 Nm).
     
    Spark plugs and plug wires
     

  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Wheelhouse panel
     
    Oil dipstick tube, right side only
     
    Secondary Air Injection (AIR) pipe nut from the fuel rail stud, if equipped
     
    AIR pipe bolts from the exhaust manifold
     
    AIR pipe from the AIR pump pipe
     
    AIR pipe gasket and discard
     
    Spark plug wires from the spark plugs and ignition coils, by first twisting the boot 1 / 2 turn in each direction and pulling off using the boot. Do not pull on the wire!
     
    Spark plugs
     

  4.  
  5. If removing the right exhaust manifold, perform the following:
    1. Remove the Exhaust Gas Recirculation (EGR) pipe nuts from the manifold.
    2.  
    3. Remove the EGR pipe bracket bolt.
    4.  
    5. Remove and discard the EGR pipe gasket.
    6.  
    7. Reposition the EGR pipe.
    8.  

  6.  
  7. Raise and support the vehicle.

    Exhaust manifold heat shield bolts and shield
     

  8.  
  9. Lower the vehicle.

    Exhaust manifold bolt and nuts
     
    Exhaust manifold
     
    Exhaust manifold gasket and discard
     

  10.  

To install:

  1. Clean the mating surfaces and the retainer threads.
  2.  
  3. Install or connect the following:

    New exhaust manifold gasket
     
    Exhaust manifold
     
    Exhaust manifold bolt and nuts. Tighten the bolt to 26 ft. lbs. (35 Nm) and the nuts to 12 ft. lbs. (16 Nm)
     

  4.  
  5. Raise the vehicle.

    Heat shield. Tighten the retaining bolts and nuts to 18 ft. lbs. (25 Nm)
     

  6.  
  7. Lower the vehicle.

    EGR pipe, right side only. Tighten the pipe bracket bolt to 37 ft. lbs. (50 Nm) and the nuts to 22 ft. lbs. (30 Nm)
     
    Spark plugs and plug wires
     
    Air pipe, using a new gasket and reversing the removal procedure
     
    Wheel house panel
     

  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Wheelhouse panel
     
    Oil dipstick tube, right side only
     
    Secondary Air Injection (AIR) pipe nut from the fuel rail stud, if equipped
     
    AIR pipe bolts from the exhaust manifold
     
    AIR pipe from the AIR pump pipe
     
    AIR pipe gasket and discard
     
    Spark plug wires from the spark plugs and ignition coils, by first twisting the boot 1 / 2 turn in each direction and pulling off using the boot. Do not pull on the wire!
     
    Spark plugs
     

  4.  
  5. If removing the right exhaust manifold, perform the following:
    1. Remove the Exhaust Gas Recirculation (EGR) pipe nuts from the manifold.
    2.  
    3. Remove the EGR pipe bracket bolt.
    4.  
    5. Remove and discard the EGR pipe gasket.
    6.  
    7. Reposition the EGR pipe.
    8.  

  6.  
  7. Raise and support the vehicle.

    Exhaust manifold heat shield bolts and shield
     

  8.  
  9. Lower the vehicle.

    Exhaust manifold bolt and nuts
     
    Exhaust manifold
     
    Exhaust manifold gasket and discard
     

  10.  

To install:

  1. Clean the mating surfaces and the retainer threads.
  2.  
  3. Install or connect the following:

    New exhaust manifold gasket
     
    Exhaust manifold
     
    Exhaust manifold bolt and nuts. Tighten the bolt to 26 ft. lbs. (35 Nm) and the nuts to 12 ft. lbs. (16 Nm)
     

  4.  
  5. Raise the vehicle.

    Heat shield. Tighten the retaining bolts and nuts to 18 ft. lbs. (25 Nm)
     

  6.  
  7. Lower the vehicle.

    EGR pipe, right side only. Tighten the pipe bracket bolt to 37 ft. lbs. (50 Nm) and the nuts to 22 ft. lbs. (30 Nm)
     
    Spark plugs and plug wires
     
    Air pipe, using a new gasket and reversing the removal procedure
     
    Wheel house panel
     

  8.  

  1. Remove or disconnect the following:

    Spark plug wires
     
    Spark plugs
     
    Exhaust manifold heat shield bolts and shield
     
    Exhaust manifold bolt and nuts
     
    Exhaust manifold
     
    Exhaust manifold gasket and discard
     

  2.  

To install:

  1. Clean the mating surfaces and the retainer threads.
  2.  
  3. Install or connect the following:

    New exhaust manifold gasket
     
    Exhaust manifold
     
    Exhaust manifold bolt and nuts. Tighten the bolt to 26 ft. lbs. (35 Nm) and the nuts to 12 ft. lbs. (16 Nm).
     
    If removed, tighten the studs to 15 ft. lbs. (20 Nm).
     
    Heat shield. Tighten the retaining bolts and nuts to 18 ft. lbs. (25 Nm).
     
    Spark plugs and plug wires
     

  4.  

  1. Remove or disconnect the following:

    Spark plug wires
     
    Spark plugs
     
    Exhaust manifold heat shield bolts and shield
     
    Exhaust manifold bolt and nuts
     
    Exhaust manifold
     
    Exhaust manifold gasket and discard
     

  2.  

To install:

  1. Clean the mating surfaces and the retainer threads.
  2.  
  3. Install or connect the following:

    New exhaust manifold gasket
     
    Exhaust manifold
     
    Exhaust manifold bolt and nuts. Tighten the bolt to 26 ft. lbs. (35 Nm) and the nuts to 12 ft. lbs. (16 Nm).
     
    If removed, tighten the studs to 15 ft. lbs. (20 Nm).
     
    Heat shield. Tighten the retaining bolts and nuts to 18 ft. lbs. (25 Nm).
     
    Spark plugs and plug wires
     

  4.  

 
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