Exhaust Manifold Replacement Right

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Disconnect the exhaust pipe from the exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
3. Lower the vehicle.
4. Remove the air cleaner outlet duct from the air cleaner assembly and the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls - 4.3L.
5. Remove the secondary air injection (AIR) pipe assembly, if equipped from the exhaust manifold. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement - Bank 2 in Engine Controls - 4.3L.
6. Disconnect the spark plug wires from the spark plugs. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
7. Remove the exhaust manifold. Refer to Exhaust Manifold Removal (Right) .
8. Clean all gasket surfaces. Refer to Exhaust Manifold Clean and Inspect .



9. Remove the bolts and heat shield from the exhaust manifold, if necessary.

1. Install the heat shield to the exhaust manifold, if removed.

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.

2. Install the heat shield bolts.

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





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

3. Sub-assemble the bolts, spark plug wire shields, and NEW gaskets to the exhaust manifold.
4. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
5. Install the exhaust manifold. Refer to Exhaust Manifold Installation (Right) .
6. Install the AIR pipe assembly, if equipped to the exhaust manifold. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement - Bank 2 in Engine Controls - 4.3L.
7. Connect the spark plug wires to the spark plugs. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
8. Raise the vehicle.
9. Connect the exhaust pipe to the exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
10. Lower the vehicle.
11. Install the air cleaner outlet duct to the air cleaner assembly and the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls - 4.3L.

Exhaust Manifold Replacement Left

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle
2. Disconnect the exhaust pipe from the exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
3. Lower the vehicle.
4. Remove the secondary air injection (AIR) pipe assembly, if equipped from the exhaust manifold. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement - Bank 1 in Engine Controls - 4.3L.
5. Disconnect the spark plug wires from the spark plugs. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.



6. Disconnect the exhaust gas recirculation (EGR) valve inlet pipe from the exhaust manifold.



7. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
8. Remove the exhaust manifold. Refer to Exhaust Manifold Removal (Left) .
9. Clean all gasket surfaces. Refer to Exhaust Manifold Clean and Inspect .



10. Remove the bolts and the heat shield from the exhaust manifold, if necessary.

1. Install the heat shield to the exhaust manifold, if removed.

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.

2. Install the heat shield bolts.

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





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

3. Sub-assemble the bolts, spark plug wire shields, and NEW gaskets to the exhaust manifold.
4. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
5. Install the exhaust manifold. Refer to Exhaust Manifold Installation (Left) .



6. Connect the EGR valve inlet pipe to the exhaust manifold.

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




7. Connect the ECT sensor electrical connector.
8. Connect the spark plug wires to the spark plugs. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
9. Install the AIR pipe assembly to the exhaust manifold. Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement - Bank 1 in Engine Controls - 4.3L.
10. Raise the vehicle.
11. Connect the exhaust pipe to the exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
12. Lower the vehicle.