GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1996 🢒 Chevy G Van 🢒 Engine 🢒 Engine Mechanical - 5.0L and 5.7L 🢒 Exhaust Manifold Replacement

Removal Procedure
  1. Disconnect the battery negative cable assembly from the battery negative terminal. 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 Engine Cover in Interior Trim.
  3. Remove the coolant reservoir. Refer to Coolant Reservoir Replacement in Engine Cooling.
  4. Remove the air cleaner assembly and intake duct.
  5. Remove the EGR inlet tube (left side).
  6. Remove the oil level indicator tube bracket (right side).
  7. Remove the spark plugs and wires. Refer to Spark Plug Replacement in Engine Electrical.
  8. Raise the vehicle. Refer to General Information.
  9. Support the vehicle with safety stands.
  10. Remove the exhaust pipe at the manifold. Refer to Removing Exhaust Parts in Exhaust System.

    11. Object Number: 64925 Size: SH
  11. Remove the exhaust manifold bolts and heat shields.
  12. Remove the exhaust manifold and gasket.
  13. Clean the mating surfaces on the manifold and the head.
  14. Clean the threads on the exhaust manifold bolts.

Installation Procedure

    Object Number: 64925 Size: SH
  1. Install the exhaust manifold and gasket to the cylinder head.
  2. Install the exhaust manifold heat shields and bolts.
  3. Tighten the bolts in two steps:

    4. Tighten

    1. Tighten the bolts on the first pass in sequence to 15 N·m (11 lb ft)
    2. Tighten the bolts on the final pass in sequence 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.

  4. Install the exhaust pipes to the manifolds. Refer to Exhaust Pipe Replacement in Engine Exhaust.
  5. Remove the safety stands.
  6. Lower the vehicle.
  7. Install the oil level indicator tube bracket (right side).
  8. Install the EGR inlet tube (left side).
  9. Install the spark plugs and wires. Refer to Spark Plug Replacement in Engine Electrical.
  10. Install the air cleaner assembly and the intake duct.
  11. Install the coolant reservoir. Refer to Coolant Reservoir Replacement in Engine Cooling.
  12. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  13. Connect the battery negative cable assembly to the battery negative terminal.

    14. Tighten
    Tighten the bolt to 15 N·m (11 lb ft).