Exhaust Manifold Replacement - Right

Exhaust Manifold Replacement - Right (4.8L, 5.3L, and 6.01- Engines)





1. Remove the ignition coils. Refer to Ignition Coil(s) Replacement in Engine Controls - 4.8L, 5.3L, and 6.OL.
2. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 4.8L, 5.3L, and 6.OL.
3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the exhaust manifold pipe nuts.
5. Lower the vehicle.





6. If equipped, remove the bolts (1, 2, and 3) attaching the exhaust gas recirculation (EGR) valve pipe to the following:
- Intake manifold
- Cylinder head
- Exhaust manifold
7. Remove the EGR valve pipe and gaskets, if equipped.
With mild force, pull the EGR valve pipe from the intake manifold.
8. Remove the O-ring seal from the EGR valve pipe, if equipped.
9. Discard the gasket and the O-ring seal.





10. Remove the exhaust manifold bolts, manifold, and gasket.
11. Discard the gasket.





12. Remove the heat shield bolts (1), and shield (2) from the exhaust manifold (1), if necessary.
13. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection in Engine Mechanical - 4.81L, 5.31L, and 6.01- Unit Repair.

Installation Procedure





Notice: Refer to Fastener Notice in Cautions and Notices.

1. Install the heat shield (2), and bolts (1) to the exhaust manifold (1), if necessary.
- Tighten the bolts to 9 Nm (80 inch lbs.).





Important:
- Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance.
- The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material.
- Do not apply sealant to the first three threads of the bolt.

2. Apply a 5 mm (0.2 inch) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts.
3. Install the exhaust manifold, NEW gasket and bolts.

3.1. Tighten the exhaust manifold bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
3.2. Tighten the exhaust manifold bolts a final pass to 25 Nm (18 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.





5. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe.
6. Install the EGR pipe.
7. Install the EGR valve pipe bolts until snug.
7.1. Tighten the intake manifold bolt (1) to 10 Nm (89 inch lbs.).
7.2. Tighten the cylinder head bolts (2) to 50 Nm (37 ft. lbs.).
7.3. Tighten the exhaust manifold bolts (3) to 30 Nm (22 ft. lbs.).
8. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 4.8L, 5.3L, and 6.OL.
9. Install the ignition coils. Refer to Ignition Coil(s) Replacement in Engine Controls - 4.8L, 5.3L, and 6.OL.
10. Raise the vehicle.





11. Install the exhaust manifold pipe nuts.
- Tighten the nuts to 50 Nm (37 ft. lbs.).
12. Lower the vehicle.