GM Cutlass RWD 1970-1987 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4 and 5

L-6 Engine

Up until 1975, the exhaust manifold is removed with the intake manifold. See the section on intake manifold removal. For 1975 and later models, use the following procedure.

  1. Remove the air cleaner.
  2.  
  3. If equipped with power steering, remove the power steering pump and bracket. Leave the pump hoses connected and set the pump out of the way.
  4.  
  5. If so equipped, remove the air pump bracket.
  6.  
  7. Remove the EFE valve bracket.
  8.  
  9. Remove the throttle linkage and throttle return springs.
  10.  
  11. Unbolt the exhaust manifold from the exhaust pipe. Spray the threads with rust penetrant first.
  12.  
  13. Remove the manifold bolts and remove the exhaust manifold.
  14.  

To install:
  1. Clean and oil all the manifold-to-head bolts.
  2.  
  3. When installing the manifold, torque the bolts in stages to the specified torque in the proper sequence.
  4.  
  5. Install the throttle return springs and linkage.
  6.  
  7. Install the EFE bracket and the air pump bracket (if equipped)
  8.  
  9. Connect the power pump and bracket and pump (if equipped)
  10.  
  11. Install the air cleaner.
  12.  



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Fig. Fig. 1: Disconnect the exhaust crossover pipe from the manifold



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Fig. Fig. 2: Remove the exhaust manifold attaching bolts



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Fig. Fig. 3: Remove the hot air shroud



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Fig. Fig. 4: Remove the exhaust manifold



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Fig. Fig. 5: Remove the exhaust manifold gasket

Buick Built Engines
  1. Raise the vehicle and support on jackstands.
  2.  
  3. Disconnect the exhaust crossover pipe from the manifolds on both sides of the engine and lower it. On the V6, disconnect the choke pipe if you are working on the right side, the EFE line if you are working on the left side.
  4.  
  5. If equipped with manual transmission, remove the equalizer shaft.
  6.  
  7. Remove the exhaust manifold-to-cylinder head bolts.
  8.  
  9. Remove the manifold from beneath the car.
  10.  
  11. Reverse the above to install. Always use the bolt locks.
  12.  

V8 Chevrolet Built Engines
LEFT SIDE
  1. Disconnect the battery ground cable. Raise the vehicle and support it with jackstands. Unbolt the exhaust pipe at the manifold.
  2.  
  3. Unbolt the front manifold to exhaust pipe flange stud, and then remove the rear spark plug shield; lower the vehicle.
  4.  
  5. Remove the air conditioning compressor and set it aside. DO NOT disconnect any air conditioning lines.
  6.  
  7. Disconnect and label the spark plug wires and their holder, the temperature sending unit lead and the dipstick.
  8.  
  9. Remove the attaching bolts and remove the manifold.
  10.  
  11. To install, reverse the removal procedure.
  12.  

RIGHT SIDE
  1. Disconnect the ground cable, and remove the fan shroud upper bolts and loosen the fan shroud. Remove the air cleaner intake pipe. If equipped with an air pump, remove the air injector manifold assembly.
  2.  
  3. Raise the car and support it with jackstands, disconnect the exhaust pipe at the manifold.
  4.  
  5. On some models, there will not be enough clearance to remove the manifold. If so, perform the following: Remove the right side engine mounting bracket through bolt, and loosen the left side mounting bracket through bolt. Jack up the right side of the engine, reinstall the right side through bolt, and lower the engine until the through bolt is resting on the mounting bracket.
  6.  
  7. Remove the rear spark plug shield bolt.
  8.  
  9. Lower the car and remove the spark plug wires (label them first), air cleaner heat stove pipe, and the air cleaner intake pipe. Remove the rear spark plug shield.
  10.  
  11. Remove the manifold to engine bolts, and remove the manifold, the EFE valve and the vacuum can.
  12.  
  13. To install, reverse the removal procedure.
  14.  

350, 403, 455 Oldsmobile Built Gasoline Engines 1970-77
  1. Disconnect the negative battery cable and remove the air cleaner.
  2.  
  3. Remove the alternator and the alternator bracket.
  4.  
  5. Raise the car and support it with jackstands.
  6.  
  7. If the car is equipped with a crossover pipe, remove the bolts from the exhaust manifold flanges and remove the crossover pipe.
  8.  
  9. On cars equipped with air-conditioning, it will be necessary to remove the right front wheel to gain access to the right-hand manifold through the opening in the inner fender panel.
  10.  
  11. If the car is equipped with hot-air shrouds, remove them from the manifolds.
  12.  
  13. Unbolt the exhaust pipes from the exhaust manifolds. Spray the manifold studs with a penetrating lubricant first.
  14.  
  15. Remove the bolts which attach the manifolds to the cylinder heads, and remove the manifolds.
  16.  
  17. Installation is in the reverse order of removal.
  18.  

260, 350, 307 Oldsmobile Built Gasoline Engines 1978-87
RIGHT SIDE
  1. Raise and support the car on jackstands.
  2.  
  3. Disconnect the exhaust crossover pipe.
  4.  
  5. Disconnect the exhaust pipe.
  6.  
  7. Unbolt and remove the manifold.
  8.  
  9. Installation is the reverse of removal.
  10.  

LEFT SIDE
  1. Raise and support the car on jackstands.
  2.  
  3. Disconnect the crossover pipe.
  4.  
  5. Lower the car.
  6.  
  7. Disconnect the steering intermediate shaft.
  8.  
  9. Remove the heat shroud.
  10.  
  11. Unbolt and remove the manifold.
  12.  
  13. Installation is the reverse of removal.
  14.  

260, 263 and 350 Oldsmobile Built Diesel Engines
  1. Drain the cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the air cleaner.
  2.  
  3. Disconnect the upper radiator hose and thermostat bypass hose from the water outlet.
  4.  
  5. Disconnect the heater inlet hose and the AC vacuum line from the water valve.
  6.  
  7. Remove the crankcase ventilation pipes from the air crossover (V6) or valve covers (V8).
  8.  
  9. Remove the fuel pump and immediately cap all pipe openings.
  10.  
  11. Remove the fuel injection pump.
  12.  
  13. Disconnect all wiring and remaining hoses from the manifold.
  14.  
  15. Remove the cruise control servo.
  16.  
  17. Remove the intermediate pump adapter.
  18.  
  19. Unbolt and remove the manifold and adapter seal.
  20.  

To install:
  1. Clean all gasket surfaces thoroughly.
  2.  
  3. Coat both sides of the new gaskets with sealer.
  4.  
  5. Position the gasket on the engine. Install the end seals making sure that their ends are under the heads.
  6.  

The seals and their mating surfaces must be dry. Apply a bead of RTV silicone sealer at the ends of the seals.

  1. Apply chassis lube to the seal area of the intake manifold and pump adapter.
  2.  
  3. Position the intake manifold on the engine and connect the thermostat bypass hose. Dip the bolts in oil and torque them in sequence to 15 ft. lbs. (20 Nm) Then, retorque them in sequence to 40 ft. lbs.(54 Nm)
  4.  
  5. Install the intermediate pump adaptor and the cruise control servo
  6.  
  7. Connect the hoses, wiring and the fuel pump
  8.  
  9. Connect the crankcase ventilation pipes on the air crossover (V6) or valve covers (V8)
  10.  
  11. Connect the AC vacuum line and the heater inlet hose
  12.  
  13. Connect the thermostat bypass hose and the upper radiator hose
  14.  
  15. Install the air cleaner and fill the radiator with coolant
  16.  

 
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