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

Removal Procedure

    Object Number: 651872 Size: SH
  1. Remove the fuel rail cover.
  2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .

    3. Object Number: 676192 Size: SH
  3. Remove the exhaust manifold nuts. (left side shown, right side similar)

    4. Object Number: 676532 Size: SH
  4. Remove the connector position assurance (CPA) lock.
  5. Disconnect the oxygen sensor electrical connector.

    6. 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.

  6. Remove the oxygen sensor.
  7. Lower the vehicle.

    8. Object Number: 651875 Size: SH
  8. Remove the hose clamp at the right check valve.
  9. Remove the secondary air injection (AIR) pipe hose (1) from the right check valve.

    10. Object Number: 651878 Size: SH
  10. Loosen, DO NOT remove the AIR pipe bolt at the rear of the left cylinder head.

    11. Object Number: 651877 Size: SH

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

  11. Remove the AIR pipe bolts.
  12. Reposition the AIR pipe.
  13. Remove the old AIR pipe gasket. Discard the gasket
  14. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .

    15. Object Number: 697216 Size: SH
  15. Remove the ignition coil bracket studs.
  16. Remove the ignition coil bracket.
  17. Remove the spark plugs. Refer to Spark Plug Replacement .

    18. Object Number: 639833 Size: SH
  18. Remove and discard the exhaust manifold bolts.
  19. Remove the exhaust manifold, and old gasket. Discard the gasket.
  20. 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 - Right Side .

    2. Object Number: 697216 Size: SH
  2. Install the ignition coil bracket.
  3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the bracket studs.

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

  4. Install the ignition coil bracket studs.

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

  5. Install the spark plugs. Refer to Spark Plug Replacement .
  6. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .

    7. Object Number: 651877 Size: SH

    Important: Ensure that the AIR pipe bracket slides behind the bolt at the left cylinder head.

  7. Position the AIR pipe (with check valve) and NEW gasket into place.
  8. Install the AIR pipe bolts.

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


    Object Number: 651878 Size: SH
  9. Tighten the AIR pipe bolt at the rear of the left cylinder head.

    10. Tighten
    Tighten the AIR pipe bolt to 20 N·m (15 lb ft).


    Object Number: 651875 Size: SH
  10. Install the AIR pipe hose (1) to the right check valve.
  11. Install the hose clamp at the right check valve.
  12. Raise the vehicle.

    13. Object Number: 676532 Size: SH
  13. Apply anti-sieze compound GM P/N 12377953 or equivalent to the threads of the oxygen sensor.

    14. 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.

  14. Install the oxygen sensor.

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

  15. Connect the oxygen sensor electrical connector.
  16. Install the CPA lock.

    17. Object Number: 676192 Size: SH
  17. Install the exhaust manifold nuts. (left side shown, right side similar)

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

  18. Lower the vehicle.

    19. Object Number: 651872 Size: SH
  19. Install the fuel rail cover.