Exhaust Manifold Replacement - Left Side 4.3L

1. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
2. Disconnect the engine coolant temperature (ECT) gage sensor electrical connector.



3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the left front tire.
5. Remove the left fender wheelhouse extension (1).
6. Remove the catalytic converter assembly.



7. Remove the EGR valve inlet pipe from the exhaust manifold.



8. Remove the spark plug wires from the spark plugs.
9. Remove the spark plug wire support bolts.
10. Remove the spark plug wire support with the spark plug wires.
11. Remove the spark plugs.
12. Remove the AIR pipe from the exhaust manifold.



13. Remove the exhaust manifold, gaskets and the spark plug wire shields from underneath the vehicle.
14. Clean all gasket surfaces.

Important: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and the bolts in place.

1. Sub-assemble the NEW gaskets, the spark plug wire shields, and the bolts to the exhaust manifold.
2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
3. Install the exhaust manifold.



4. Install the spark plugs.
5. Install the spark plug wires to the spark plugs.
6. Install the AIR pipe to the exhaust manifold.

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.

7. Install the spark plug wire support and bolts.

Tighten
Tighten the spark plug wire support bolts to 12 N·m (106 lb in).




8. Install the EGR valve inlet pipe to the exhaust manifold.

Tighten
Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N·m (22 lb ft).

9. Install the catalytic converter assembly.



10. Install the fender wheelhouse extension (1).
11. Install the left front tire.
12. Lower the vehicle.



13. Connect the ECT gage sensor electrical connector.
14. Install the engine cover.

Exhaust Manifold Replacement - Left Side 5.7L

1. Remove the exhaust pipe from the exhaust manifold.
2. Remove the engine cover.
3. Disconnect the EGR valve pipe from the exhaust manifold.
4. Remove the spark plugs.
5. Remove the exhaust manifold.
6. Clean all sealing surfaces.

1. Install the exhaust manifold.
2. Connect the EGR valve pipe to the manifold.
3. Install the spark plugs.
4. Install the exhaust pipe to the exhaust manifold.
5. Install the engine cover.