GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Chevy C Cab/Chassis HD (GMT 400) 🢒 Engine 🢒 Engine Cooling 🢒 Exhaust Manifold Replacement - Right Side

Removal Procedure

    Object Number: 747681 Size: SH
  1. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the catalytic converter nuts.
  3. Remove the exhaust manifold seals.
  4. Allow the catalytic converter to hang.
  5. Lower the vehicle.
  6. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical - 8.1L.

    7. Object Number: 470646 Size: SH
  7. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 8.1 L.

    8. Object Number: 470706 Size: SH
  8. Remove the exhaust manifold heat shield bolts and nuts.
  9. Remove the exhaust manifold heat shield.

    10. Object Number: 470719 Size: SH
  10. Remove the exhaust manifold bolt and nuts.
  11. Remove the exhaust manifold.
  12. Remove and discard the exhaust manifold gasket.

Installation Procedure

    Object Number: 470719 Size: SH
  1. Install a NEW exhaust manifold gasket.
  2. Install the exhaust manifold.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the exhaust manifold bolt and nuts.

    4. Tighten

        • Tighten the exhaust manifold bolt to 35 N·m (26 lb ft).
        • Tighten the exhaust manifold nuts to 16 N·m (12 lb ft).

    Object Number: 470706 Size: SH
  4. Install the exhaust manifold heat shield.
  5. Install the exhaust manifold heat shield bolts and nuts.

    6. Tighten
    Tighten the exhaust manifold heat shield bolts and nuts to 25 N·m (18 lb ft).

  6. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 8.1L.
  7. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical - 8.1L.
  8. Raise the vehicle.

    9. Object Number: 747681 Size: SH
  9. Raise the catalytic converter into position.
  10. Install the exhaust manifold seals.
  11. Install the catalytic converter nuts.

    12. Tighten
    Tighten the catalytic converter nuts to 64 N·m (47 lb ft).

  12. Lower the vehicle.