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

    Object Number: 664837 Size: SH
  1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove surge tank bolt and position surge tank aside. Refer to Radiator Surge Tank Replacement in Engine Cooling.
  3. Remove the exhaust manifold pipe nuts.
  4. Lower the vehicle.
  5. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.

    6. Object Number: 492768 Size: SH
  6. Remove the heat shield bolts (1) and shield (2) from the exhaust manifold (1).

    7. Object Number: 741554 Size: SH
  7. Remove the exhaust manifold bolts, manifold, and gasket.
  8. Discard the gasket.
  9. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection in Engine Mechanical.

Installation Procedure

    Object Number: 741554 Size: SH

    Important: 

       • Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect 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.

    Important: Do not apply sealant to the first three threads of the bolt.

  1. 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.

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

  2. Install the exhaust manifold, NEW gasket and bolts.

    3. Tighten

    1. Tighten the exhaust manifold bolts a first pass to 25 N·m (18 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work 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 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
  3. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.

    4. Object Number: 492768 Size: SH
  4. Install the heat shield (2) and bolts (1) to the exhaust manifold (1).

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

  5. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.
  6. Install surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
  7. Raise the vehicle.

    8. Object Number: 664837 Size: SH
  8. Install the exhaust manifold pipe nuts.

    9. Tighten
    Tighten the exhaust manifold pipe nuts to 50 N·m (37 lb ft).

  9. Lower the vehicle.