Camaro, Firebird, 1999 - 2002

Exhaust Manifold

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Removal & Installation



3.8L Engines
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Catalytic converter pipe
     
    Connector Position Assurance (CPA) retainer, if equipped
     
    Oxygen Sensor (O 2 S) electrical connector
     
    O 2 sensor
     
    Spark plugs
     
    Exhaust Gas Recirculation (EGR) valve adapter from the exhaust manifold, if equipped
     
    2 rear exhaust manifold studs and nut from the exhaust manifold
     
    Exhaust manifold heat shields
     
    Exhaust manifold and gasket

    Click image to see an enlarged view

    Fig. Exploded view of the EGR valve adapter and outlet pipe-3.8L engine



    Click image to see an enlarged view

    Fig. Exploded view of the right and left exhaust manifold mounting-3.8L engine

     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket. Tighten the 2 front exhaust manifold studs and nuts to the exhaust manifold to 11 ft lbs. (15 Nm) and the nuts to 13 ft. lbs. (18 Nm).
     
    Exhaust manifold heat shield and nuts. Tighten the to 89 inch lbs. (10 Nm).
     
    Spark plugs and wires
     
    2 rear exhaust manifold studs and nut to the exhaust manifold. Tighten the 2 rear exhaust manifold studs to 11 ft lbs. (15 Nm) and the nuts to 13 ft. lbs. (18 Nm).
     
    O 2 sensor
     
    Catalytic converter pipe
     
    CPA retainer, if equipped
     
    EGR valve adapter, if equipped and torque the bolt to 18 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  2.  

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

    Negative battery cable
     
    Connector Position Assurance (CPA) retainer, if equipped
     
    Exhaust catalytic converter pipe
     
    Oxygen Sensor (O 2 S) electrical connector
     
    Spark plugs and wires
     
    2 rear exhaust manifold studs and nut from the exhaust manifold
     
    Exhaust manifold heat shields
     
    Exhaust manifold and gasket

    Click image to see an enlarged view

    Fig. Exploded view of the right and left exhaust manifold mounting-3.8L engine

     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket. Tighten the 2 front exhaust manifold studs and nuts to the exhaust manifold to 11 ft lbs. (15 Nm) and the nuts to 13 ft. lbs. (18 Nm).
     
    Exhaust manifold heat shield and nuts. Tighten the to 89 inch lbs. (10 Nm).
     
    Spark plugs and wires
     
    2 rear exhaust manifold studs and nut to the exhaust manifold. Tighten the 2 rear exhaust manifold studs to 11 ft lbs. (15 Nm) and the nuts to 13 ft. lbs. (18 Nm).
     
    O 2 sensor
     
    Catalytic converter pipe
     
    CPA retainer, if equipped
     
    Negative battery cable
     

  2.  

5.7L Engines
Left Side-1999 Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Rocker arm cover
     
    Fuel lines
     
    Positive Crankcase Ventilation (PCV) hose
     
    Spark plug wires
     
    Spark plugs
     
    Secondary Air Injection (AIR) hose
     
    AIR pipe with check valve
     
    Coolant sensor
     
    Exhaust manifold bolts
     
    Oxygen Sensor (O 2 S)
     
    Exhaust manifold pipe nuts
     
    Catalytic converter nuts
     
    Exhaust manifold

    Click image to see an enlarged view

    Fig. Exploded view of right and left exhaust manifold mounting-5.7L engines

     

  6.  

To install:

Install or connect the following:



Exhaust manifold with a new gasket. Torque the catalytic converter nuts to 18 ft. lbs. (25 Nm).
 
Exhaust manifold pipe nuts. Torque the nuts to 26 ft. lbs. (35 Nm).
 
O 2 S. Torque the sensor to 31 ft. lbs. (42 Nm).
 
Exhaust manifold bolts. Torque the bolts to 18 ft. lbs. (25 Nm).
 
Coolant sensor
 
AIR pipe. Torque the bolts to 15 ft. lbs. (20 Nm).
 
AIR hose
 
Spark plugs. Torque the spark plugs to 11 ft. lbs. (15 Nm).
 
Spark plug wires
 
PCV hose
 
Fuel lines
 
Negative battery cable
 

Left Side-2000-02 Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Rocker arm cover
     
    Spark plug wires
     
    Spark plugs
     
    Left side catalytic converter
     
    Exhaust manifold bolts
     
    Exhaust manifold and gasket

    Click image to see an enlarged view

    Fig. Exploded view of right and left exhaust manifold mounting-5.7L engines

     

  4.  

To install:

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

  6.  
  7. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the cylinder head.
  8.  

Install or connect the following:



Left side catalytic converter
 
Rocker arm cover
 
Spark plug wires
 
Spark plugs
 
Negative battery cable
 

Right Side-1999 Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Oil level indicator and tube
     
    Exhaust manifold pipe nuts
     
    Secondary Air Injection (AIR) hose
     
    AIR pipe with check valve
     
    Ignition coil main electrical connector
     
    Spark plug wires
     
    Spark plugs
     
    Rocker arm cover
     
    Exhaust Gas Recirculation (EGR) valve electrical connector
     
    EGR valve pipe
     
    Exhaust manifold

    Click image to see an enlarged view

    Fig. Exploded view of right and left exhaust manifold mounting-5.7L engines

     

  4.  

To install:

  1. Install the exhaust manifold with a new gasket. Torque the bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Install the EGR valve pipe. Torque the bolts as follows:
    1. EGR valve pipe-to-exhaust manifold bolts to 18 ft. lbs. (25 Nm).
    2.  
    3. EGR valve pipe-to-cylinder head bolt to 37 ft. lbs. (50 Nm).
    4.  
    5. EGR valve pipe-to-throttle body bolt to 106 inch lbs. (12 Nm).
    6.  

  4.  
  5. Install or connect the following:

    EGR valve electrical connector
     
    Rocker arm cover. Torque the bolts to 106 inch lbs. (12 Nm).
     
    Spark plugs. Torque the spark plugs to 12 ft. lbs. (15 Nm).
     
    Spark plug wires
     
    Ignition coil main electrical connector
     
    AIR pipe. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    AIR hose
     
    Exhaust manifold pipe nuts. Torque the nuts to 26 ft. lbs. (35 Nm).
     
    Oil level indicator and tube
     
    Negative battery cable
     

  6.  

Right Side-2000-02 Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Rocker arm cover
     
    Spark plug wires
     
    Spark plugs
     
    Right side catalytic converter
     
    Exhaust Gas Recirculation (EGR) valve electrical connector
     
    EGR valve pipe bolts
     
    EGR valve pipe up out of the intake manifold, using mild force
     
    O-ring seal from the EGR valve pipe. Discard the exhaust manifold gasket and O-ring seal.
     
    Exhaust manifold bolts
     
    Exhaust manifold and gasket

    Click image to see an enlarged view

    Fig. Exploded view of right and left exhaust manifold mounting-5.7L engines

     

  4.  

To install:

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

  6.  
  7. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the cylinder head.
  8.  
  9. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe.
  10.  
  11. Install the EGR valve pipe into the intake manifold. Finger start the EGR valve pipe to the intake manifold bolt and the EGR valve pipe to the cylinder head bolts.
  12.  
  13. Finger start a NEW EGR valve pipe exhaust manifold gasket and bolts and tighten as follows:
    1. Tighten the EGR valve pipe-to-intake manifold bolt to 89 inch lbs. (10 Nm).
    2.  
    3. Tighten the EGR valve pipe-to-cylinder head bolts to 37 ft. lbs. (50 Nm).
    4.  
    5. Tighten the EGR valve pipe to the exhaust manifold bolts to 22 ft. lbs. (30 Nm).
    6.  

  14.  

Install or connect the following:



EGR solenoid electrical connector
 
Right side catalytic converter
 
Rocker arm cover
 
Spark plug wires
 
Spark plugs
 
Negative battery cable
 

 
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