Corvette 1997-2005

Exhaust Manifold

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Removal & Installation



5.7L Engines
Left Side


Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold-5.7L engine, 6.0L engine similar

  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
     
    Fuel rail cover
     
    Alternator
     
    Exhaust manifold nuts
     
    Connector Position Assurance (CPA) lock
     
    Oxygen Sensor (O 2 S)
     
    O 2 S connector clip at the body
     
    Secondary Air Injection (AIR) hose clamp
     
    AIR hose from the pipe
     
    Hose clamps at the right and left check valves
     
    AIR injection pipe hose from the right check valve
     
    AIR injection pipe hose from the left check valve
     
    AIR pipe
     
    AIR pipe and gasket, and discard the old gasket
     
    Brake booster vacuum hose from the booster
     
    Ignition coil bracket
     
    Spark plugs
     
    Exhaust manifold
     

  6.  

To install:

  1. Apply threadlock to the threads of the bolts.
  2.  
  3. Install the exhaust manifold using a new gasket.
  4.  
  5. Beginning with the center 2 bolts, torque the bolts to 11 ft. lbs. (15 Nm) alternating from side-to-side until all the bolts are tight. Torque the bolts again in the same sequence to 18 ft. lbs. (25 Nm).
  6.  
  7. Bend over the exposed portion of the gasket at the rear of the cylinder head.
  8.  
  9. Install or connect the following:

    Spark plugs and torque them to 11 ft. lbs. (15 Nm)
     
    Ignition coil bracket and tighten to 106 inch lbs. (12 Nm)
     
    Brake booster vacuum hose
     
    AIR pipe and gasket
     
    AIR pipe bolts and tighten to 15 ft. lbs. (20 Nm)
     
    AIR injection pipe hose to the left check valve
     
    AIR injection pipe hose to the right check valve
     
    Hose clamps at the right and left check valves
     
    AIR hose to the pipe
     
    AIR hose clamp
     
    O 2 S and tighten to 30 ft. lbs. (40 Nm)
     
    O 2 S connector clip at the body
     
    CPA lock
     
    Exhaust manifold nuts and tighten to 15 ft. lbs. (20 Nm)
     
    Alternator
     
    Fuel rail cover
     
    Negative battery cable
     

  10.  

Right Side
  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
     
    Fuel rail cover
     
    Exhaust manifold nuts
     
    Connector Position Assurance (CPA) lock
     
    Oxygen (O 2 S) sensor
     
    Secondary Air Injection (AIR) hose from the right check valve
     

  6.  
  7. Loosen, DO NOT remove the AIR pipe bolt at the rear of the left cylinder head.

    AIR pipe and gasket, and discard the old gasket
     
    Oil level indicator tube
     
    Ignition coil bracket
     
    Spark plugs
     
    Exhaust manifold
     

  8.  

To install:

  1. Apply threadlock to the threads of the bolts.
  2.  
  3. Install the exhaust manifold using a new gasket.
  4.  
  5. Beginning with the center 2 bolts, torque the bolts to 11 ft. lbs. (15 Nm) alternating from side-to-side until all the bolts are tight. Torque the bolts again in the same sequence to 18 ft. lbs. (25 Nm).
  6.  
  7. Bend over the exposed portion of the gasket at the rear of the cylinder head.
  8.  
  9. Install or connect the following:

    Spark plugs and torque them to 11 ft. lbs. (15 Nm)
     
    Ignition coil bracket and tighten to 106 inch lbs. (12 Nm)
     
    Oil level indicator tube
     
    AIR pipe and gasket
     
    AIR pipe bolts and tighten to 15 ft. lbs. (20 Nm)
     
    AIR injection pipe to the right check valve
     
    Hose clamps at the right check valve
     
    O 2 S and tighten to 30 ft. lbs. (40 Nm)
     
    CPA lock
     
    Exhaust manifold nuts and tighten to 15 ft. lbs. (20 Nm)
     
    Alternator
     
    Fuel rail cover
     
    Negative battery cable
     

  10.  

6.0L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine sight cover
     
    Bank 1, sensor 1 Oxygen (O 2 ) sensor from exhaust manifold
     
    Spark plugs
     
    Alternator
     
    Intermediate pipe
     
    Catalytic converter O 2 sensor electrical connectors
     
    Left catalytic converter
     
    Exhaust manifold mounting bolts
     
    Exhaust manifold
     

  4.  

To install:

  1. Install the intermediate pipe.
  2.  
  3. Position the catalytic converter on the intermediate pipe but do not tighten the clamp at this time.
  4.  
  5. Connect the catalytic converter O 2 sensor electrical connectors.
  6.  
  7. Position the exhaust manifold with a new gasket into place.
  8.  
  9. Tighten the exhaust manifold mounting bolts as follows:
    1. Step 1: Tighten to 11 ft. lbs. (15 Nm). Start with the center 2 bolts and alternate side-to-side working toward the outside bolts.
    2.  
    3. Step 2: Tighten to 18 ft. lbs. (25 Nm). Start with the center 2 bolts and alternate side-to-side working toward the outside bolts.
    4.  

  10.  
  11. Install or connect the following:

    Bank 1, sensor 1 O 2 sensor to the exhaust manifold
     
    Spark plugs
     
    Alternator
     
    Catalytic converter to exhaust manifold nuts and tighten to 15 ft. lbs. (20 Nm)
     
    Tighten the catalytic converter exhaust clamp to 15 ft. lbs. (20 Nm)
     
    Engine sight cover
     
    Negative battery cable
     

  12.  
  13. Start the engine and check for leaks.
  14.  

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

    Negative battery cable
     
    Engine sight cover
     
    Spark plugs
     
    Bank 2, sensor 1 Oxygen (O 2 ) sensor from the exhaust manifold
     
    Oil level indicator tube assembly
     
    Intermediate pipe
     
    Catalytic converter O 2 electrical connectors
     
    Right catalytic converter
     
    Exhaust manifold mounting bolts
     
    Exhaust manifold
     

  4.  

To install:

  1. Install the intermediate pipe.
  2.  
  3. Position the catalytic converter on the intermediate pipe but do not tighten the clamp at this time.
  4.  
  5. Connect the catalytic converter O 2 electrical connectors.
  6.  
  7. Install the exhaust manifold and gasket.
  8.  
  9. Tighten the exhaust manifold mounting bolts as follows:
    1. Step 1: Tighten to 11 ft. lbs. (15 Nm). Start with the center 2 bolts and alternate side-to-side working toward the outside bolts.
    2.  
    3. Step 2: Tighten to 18 ft. lbs. (25 Nm). Start with the center 2 bolts and alternate side-to-side working toward the outside bolts.
    4.  

  10.  
  11. Install or connect the following:

    Oil level indicator tube assembly. Tighten to the mounting bolt to 18 ft. lbs. (25 Nm).
     
    Spark plugs
     
    Bank 2, sensor 1 O 2 sensor
     
    Catalytic converter to exhaust manifold nuts and tighten to 15 ft. lbs. (20 Nm)
     
    Tighten the catalytic converter exhaust clamp to 15 ft. lbs. (20 Nm)
     
    Engine sight cover
     
    Negative battery cable
     

  12.  
  13. Start the engine and check for leaks.
  14.  

Left Rear
  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
     
    Left hand intermediate pipe flange nuts from the exhaust manifold studs
     
    Heated Oxygen (HO 2 S) sensor
     
    Fuel rail cover
     
    Alternator and Engine Coolant Temperature (ECT) sensor electrical connectors
     
    Drive belt
     
    Alternator
     
    Secondary Air Injection (AIR) hose from the check valve
     
    Air pipe from the exhaust manifold and reposition it
     
    Air pipe retainer from the rear of the cylinder head and reposition it
     
    Spark plug wires from the coils
     
    Spark plugs
     
    Exhaust manifold and discard the gasket

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold-5.7L engine

     

  6.  

To install:

  1. Clean the bolt holes and the mounting surface of the cylinder head.
  2.  
  3. Apply threadlock to the threads of the bolts. Do not apply it to the first 3 threads.
  4.  
  5. Install or connect the following:

    New gasket
     
    Exhaust manifold and bolts
     

  6.  
  7. Beginning with the center 2 bolts, torque the bolts to 11 ft. inch lbs. (15 Nm) alternating from side-to-side until all the bolts are tight. Torque the bolts again in the same sequence to 18 ft. lbs. (25 Nm).
  8.  
  9. Bend over the exposed portion of the gasket at the rear of the cylinder head.
  10.  
  11. Install or connect the following:

    Spark plug wires to the spark plugs and the ignition coils
     
    AIR pipe and gasket to the exhaust manifold. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    AIR pipe retainer bolt to the rear of the cylinder head. Torque the bolt to 15 ft. lbs. (20 Nm).
     
    AIR hose to the check valve. Torque the hose to 15 ft. lbs. (20 Nm).
     
    Alternator
     
    Drive belt
     
    Alternator and ECT sensor connectors
     
    Fuel rail cover
     
    Heated Oxygen (HO 2 S) sensor
     
    Fuel lines
     
    Intermediate pipe flange to exhaust manifold studs. Torque the nuts to 15 ft. lbs. (20 Nm).
     
    Negative battery cable
     

  12.  
  13. Start the vehicle and check for leaks, repair if necessary.
  14.  

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

    Negative battery cable
     
    Engine sight cover
     
    Bank 1, sensor 1 Oxygen (O 2 ) sensor from exhaust manifold
     
    Spark plug wires and spark plugs
     
    Alternator
     
    Intermediate pipe
     
    Catalytic converter O 2 sensor electrical connectors
     
    Left catalytic converter
     
    Exhaust manifold mounting bolts
     
    Exhaust manifold
     

  4.  

To install:


NOTE
The cylinder head exhaust manifold bolt hole threads must be cleaned and free of debris or threadlocking material.

  1. Install the intermediate pipe.
  2.  
  3. Position the catalytic converter on the intermediate pipe but do not tighten the clamp at this time.
  4.  
  5. Connect the catalytic converter O 2 sensor electrical connectors.
  6.  
  7. Position the exhaust manifold with a new gasket into place.
  8.  
  9. Apply a 5 mm (0.2 inch) wide band of threadlock to the threads of the exhaust manifold bolts and install.
  10.  
  11. Tighten the exhaust manifold mounting bolts as follows:
    NOTE
    Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may effect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance.

    1. Step 1: Tighten to 11 ft. lbs. (15 Nm). Start with the center 2 bolts and alternate side-to-side working toward the outside bolts.
    2.  
    3. Step 2: Tighten to 18 ft. lbs. (25 Nm). Start with the center 2 bolts and alternate side-to-side working toward the outside bolts.
    4.  

  12.  
  13. Install the bank 1, sensor 1 O 2 sensor to the exhaust manifold.
  14.  
  15. Install the spark plugs and wires.
  16.  
  17. Install the alternator.
  18.  
  19. Install the catalytic converter to exhaust manifold nuts and tighten to:

    6.0L engines 15 ft. lbs. (20 Nm).
     
    6.2L and 7.0L engines 37 ft. lbs.(50 Nm).
     

  20.  
  21. Tighten the catalytic converter exhaust clamp to 15 ft. lbs. (20 Nm).
  22.  
  23. Install the engine sight cover.
  24.  
  25. Install the negative battery cable.
  26.  
  27. Start the engine and check for leaks.
  28.  

 
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