GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Corvette 🢒 Engine 🢒 Engine Mechanical - 5.7L 🢒 Exhaust Manifold Replacement - Left Side

Removal Procedure

    Object Number: 651873 Size: SH
  1. Remove the fuel rail cover.
  2. Remove the generator. Refer to Generator Replacement .
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .

    4. Object Number: 676192 Size: SH
  4. Remove the exhaust manifold nuts.

    5. Object Number: 53269 Size: SH
  5. Remove the connector position assurance (CPA) lock.
  6. Disconnect the oxygen sensor electrical connector.
  7. Remove the oxygen sensor connector clip at the body.

    8. Notice: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning solvents on the sensor. Do not drop or mishandle the sensor.

  8. Remove the oxygen sensor.
  9. Lower the vehicle.

    10. Object Number: 651891 Size: SH
  10. Remove the hose clamp at the secondary air injection (AIR) pipe.
  11. Remove the AIR hose from the AIR pipe.

    12. Object Number: 651875 Size: SH
  12. Remove the hose clamps at the right and left check valves.
  13. Remove the AIR injection pipe hose (1) from the right check valve.
  14. Remove the AIR injection pipe hose (3) from the left check valve.
  15. Remove the AIR pipe (2).

    16. Object Number: 651876 Size: SH

    Important: Do not remove the check valve from the AIR pipe unless valve service is required.

  16. Remove the AIR pipe bolts.
  17. Remove the AIR pipe and gasket. Discard the old gasket

    18. Object Number: 63936 Size: SH
  18. Remove the brake booster vacuum hose from the brake booster.

    19. Object Number: 697215 Size: SH
  19. Remove the ignition coil bracket studs.
  20. Remove the ignition coil bracket.
  21. Remove the spark plugs. Refer to Spark Plug Replacement .

    22. Object Number: 639834 Size: SH
  22. Remove and discard the exhaust manifold bolts.
  23. Remove the exhaust manifold, and old gasket. Discard the gasket.
  24. If necessary, remove the exhaust manifold heat shield bolts and shield.

Installation Procedure
  1. Install the exhaust manifold to the cylinder head. Refer to Exhaust Manifold Installation - Left Side .

    2. Object Number: 697215 Size: SH
  2. Install the spark plugs. Refer to Spark Plug Replacement .
  3. Place the ignition coil bracket into place.
  4. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the coil bracket studs.

    5. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the ignition coil bracket studs.

    6. Tighten
    Tighten the ignition coil bracket studs to 12 N·m (106 lb in).


    Object Number: 63936 Size: SH
  6. Install the brake booster vacuum hose to the brake booster.

    7. Object Number: 651876 Size: SH
  7. Install the AIR pipe (with check valve) and a NEW gasket.
  8. Install the AIR pipe bolts.

    9. Tighten
    Tighten the AIR pipe bolts to 20 N·m (15 lb ft).


    Object Number: 651875 Size: SH
  9. Install the AIR pipe (2).
  10. Install the AIR injection pipe hose (3) to the left check valve.
  11. Install the AIR injection pipe hose (1) to the right check valve.
  12. Install the hose clamps at the right and left check valves.

    13. Object Number: 651891 Size: SH
  13. Install the AIR hose to the AIR pipe.
  14. Install the hose clamp at the AIR pipe.
  15. Raise the vehicle.

    16. Object Number: 53269 Size: SH
  16. Apply anti-sieze compound GM P/N 12377953 or equivalent to the threads of the oxygen sensor.

    17. Notice: Handle the oxygen sensors carefully in order to prevent damage to the component. Keep the electrical connector and the exhaust inlet end free of contaminants. Do not use cleaning solvents on the sensor. Do not drop or mishandle the sensor.

  17. Install the oxygen sensor.

    18. Tighten
    Tighten the oxygen sensor to 42 N·m (30 lb ft).

  18. Install the oxygen sensor connector clip at the body.
  19. Connect the oxygen sensor electrical connector.
  20. Install the CPA lock.

    21. Object Number: 676192 Size: SH
  21. Install the exhaust manifold nuts.

    22. Tighten
    Tighten the exhaust manifold nuts to 20 N·m (15 lb ft).

  22. Lower the vehicle.
  23. Install the generator. Refer to Generator Replacement .

    24. Object Number: 651873 Size: SH
  24. Install the fuel rail cover.