GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Kodiak C-Series (Conventional) C4/C5 🢒 Body 🢒 Interior Trim 🢒 Exhaust Manifold Replacement

Exhaust Manifold Replacement 7.8L With CTF

Removal Procedure
  1. Remove the front exhaust pipe. Refer to Front Pipe Replacement .
  2. Remove the exhaust gas recirculation (EGR) pipe. Refer to Exhaust Gas Recirculation Pipe Replacement .
  3. Remove the 2 heat shield bolts.
  4. Remove the turbocharger. Refer to Turbocharger Replacement .

    5. Object Number: 1369899 Size: SH
  5. Remove the exhaust manifold nuts (1-12), washers, spacers and heat shield.
  6. Remove the exhaust manifold with the gasket.

Installation Procedure

    Object Number: 1369899 Size: SH
  1. Install the exhaust manifold and gasket to the cylinder head.
  2. Install the exhaust manifold nuts, washers, spacers and the heat shield.
  3. Install the 2 heat shield bolts.
  4. Install the EGR pipe. Refer to Exhaust Gas Recirculation Pipe Replacement .

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

  5. Tighten the exhaust manifold nuts in the proper sequence.

    6. Tighten

        • Tighten the nuts (7, 12) to 34 N·m (25 lb ft).
        • Tighten the nuts (1-6, 8-11) to 55 N·m (41 lb ft).
  6. Install the turbocharger. Refer to Turbocharger Replacement .
  7. Install the front exhaust pipe. Refer to Front Pipe Replacement .