GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 1999 🢒 Savana 🢒 Engine 🢒 Engine Mechanical - 6.5L 🢒 Exhaust Manifold Replacement

Removal Procedures

    Object Number: 104973 Size: SH
  1. Disconnect the negative battery cables.
    2. • For the front battery, refer to Battery Cable Replacement in Engine Electrical.
    • For the auxiliary battery, refer to Battery Cable Replacement in Engine Electrical.
  2. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Body and Accessories.
  3. Remove the heat shield from the turbocharger. Refer to Turbocharger Replacement .
  4. Remove the engine oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement .
  5. Remove the transmission oil level indicator tube.
  6. Raise the vehicle and support with safety stands.

    7. Object Number: 65002 Size: SH
  7. Remove the glow plugs from the cylinder head.

    8. Object Number: 173010 Size: SH
  8. Remove the exhaust pipes from the exhaust manifold to the turbocharger. Refer to Turbocharger Replacement .

    9. Object Number: 68327 Size: SH
  9. Remove the exhaust manifolds from the cylinder head.
  10. Inspect and clean the sealing surfaces on the cylinder head and the exhaust manifold.

Installation Procedures

    Object Number: 68327 Size: SH
  1. Install the exhaust manifold to the cylinder head (right side shown).
  2. Install the exhaust manifold bolts (right side shown).

    3. 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.

    Tighten
    Tighten the bolts to 35 N·m (26 lb ft).


    Object Number: 173010 Size: SH
  3. Install the exhaust pipe from the turbocharger to the exhaust manifold. Refer to Turbocharger Replacement .

    4. Object Number: 65002 Size: SH
  4. Install the glow plugs in the cylinder head.
  5. Remove the safety stands and lower the vehicle. Refer to Vehicle Lifting and Jacking in General Information.

    6. Object Number: 104973 Size: SH
  6. Install the transmission oil level indicator tube.
  7. Install the engine oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement .
  8. Install the heat shield to the turbocharger assembly. Refer to Turbocharger Replacement .
  9. Install the engine cover in the vehicle. Refer to Engine Cover Replacement in Body and Accessories.
  10. Connect the battery negative cables from the batteries.
    11. • for the front battery, refer to Battery Cable Replacement in Engine Electrical.
    • For the auxiliary battery, refer to Battery Cable Replacement in Engine Electrical.