Corvette 2005-2008

Exhaust Manifold

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Removal & Installation



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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