GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Chevy G Van 🢒 Engine 🢒 Engine Mechanical - 7.4L 🢒 Exhaust Manifold Replacement

Removal Procedure
  1. Remove the negative battery cable. Refer to

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

    in General Information.
  2. Remove the engine cover. Refer to Interior Trim.
  3. Remove the oil level indicator tube on the right side exhaust manifold.
  4. Remove the EGR inlet pipe on the left side exhaust manifold.
  5. Remove the spark plugs. Refer to Spark Plugs Replacement in Engine Electrical.
  6. Remove the exhaust pipe at the exhaust manifold.

    7. Object Number: 65852 Size: SH
  7. Remove the heat shields and nuts.

    8. Object Number: 64527 Size: MH
  8. Remove the exhaust manifold and nuts.
  9. Clean the mating surfaces on the exhaust manifold and on the head.
  10. Clean the threads on the exhaust manifold mounting studs.

Installation Procedure

    Object Number: 64527 Size: MH
  1. Install the exhaust manifold.

    2. Object Number: 65852 Size: SH
  2. Install the exhaust manifold nuts.

    3. Tighten
    Tighten the nuts to 30 N·m (22 lb ft).

    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 spark plug heat shields and nuts.

    4. Tighten
    Tighten the nuts to 20 N·m (15 lb ft).

  4. Install the exhaust pipe to the exhaust manifold.
  5. Install the spark plugs. Refer to Spark Plugs Replacement in Engine Electrical.
  6. Install the EGR inlet pipe (left side exhaust manifold).
  7. Install the oil level indicator tube (right side exhaust manifold).

    8. Tighten
    Tighten the bolt to 54 N·m (40 lb ft).

  8. Install the engine cover. Refer to Interior Trim.
  9. Connect the negative battery cable.