GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 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 in General Information.

    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 in Engine Mechanical - 5.7 L.

    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 in Engine Controls - 5.7 L.

    18. Object Number: 639833 Size: SH
  18. Remove 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

Important: Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may effect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance.

The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material.


    Object Number: 639833 Size: SH

    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.

  1. If necessary, install the exhaust manifold heat shield and bolts.

    2. Tighten
    Tighten the exhaust manifold heat shield bolts to 9 N·m (80 lb in).

  2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the threads of the exhaust manifold bolts.
  3. Position the exhaust manifold and a NEW gasket into place.
  4. Install the exhaust manifold bolts.

    5. Tighten

    1. Tighten the exhaust manifold bolts a first pass to 15 N·m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, working toward the outside bolts.
    2. Tighten the exhaust manifold bolts a final pass to 25 N·m (18 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, working toward the outside bolts.
  5. Bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.

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

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

  9. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 5.7 L.
  10. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical - 5.7 L.

    11. Object Number: 651877 Size: SH

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

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

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


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

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


    Object Number: 651875 Size: SH
  14. Install the AIR pipe hose (1) to the right check valve.
  15. Install the hose clamp at the right check valve.
  16. Raise the vehicle.

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

    18. 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.

  18. Install the oxygen sensor.

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

  19. Connect the oxygen sensor electrical connector.
  20. Install the CPA lock.

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

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

  22. Lower the vehicle.

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