Escalade, Suburban, Tahoe, Yukon, Denali, DenaliXL, YukonXL 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.  

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.  

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.  

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.  

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.  

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.  

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.  

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. 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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