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. Refer to Catalytic Converter Replacement .



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 exhaust manifold, gaskets and the spark plug wire shields from underneath the vehicle.
13. 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.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the exhaust manifold.

Tighten

1. Tighten the exhaust manifold bolts - First Pass to 15 N·m (11 lb ft).
2. Tighten the exhaust manifold bolts - Second Pass to 30 N·m (22 lb ft).



4. Install the spark plugs.
5. Install the spark plug wires to the spark plugs.
6. Install the spark plug wire support and bolts.

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




7. 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).

8. Install the catalytic converter assembly. Refer to Catalytic Converter Replacement .



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



12. Connect the ECT gage sensor electrical connector.
13. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.

Exhaust Manifold Replacement - Left Side 4.8L, 5.3L, 6.0L

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .



2. Remove the catalytic converter from the exhaust manifold. Refer to Catalytic Converter Replacement .
3. Remove the engine cover. Refer to Engine Cover Replacement .
4. Disconnect the EGR valve pipe from the exhaust manifold if equipped.
5. Remove the spark plug wires.
6. Remove the exhaust manifold.
7. Clean all sealing surfaces.

Notice: Refer to Fastener Notice in the Preface section.




1. Install the exhaust manifold.

Tighten

1. Tighten the exhaust manifold bolts - First Pass to 15 N·m (11 lb ft).
2. Tighten the exhaust manifold bolts - Second Pass to 25 N·m (18 lb ft).
2. Connect the EGR valve pipe to the manifold.
3. Install the spark plug wires.
4. Install the exhaust pipe to the exhaust manifold.
5. Install the engine cover. Refer to Engine Cover Replacement .

Exhaust Manifold Replacement - Left Side 6.6L