Exhaust Manifold Replacement - Right Side 4.3L

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the right front tire.
3. Remove the right fender wheelhouse extension (1).



4. Disconnect the spark plug wires from the spark plugs.
5. Remove the bolts and the spark plug wire support.
6. Remove the starter. Refer to Starter Motor Replacement .
7. Remove the catalytic converter assembly. Refer to Catalytic Converter Replacement .



8. Remove the exhaust manifold bolts through the wheelhouse.
9. Remove the exhaust manifold with the exhaust manifold gaskets and the spark plug wire shields from the engine.
10. 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 catalytic converter assembly. Refer to Catalytic Converter Replacement .
5. Install the starter. Refer to Starter Motor Replacement .



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 spark plug wires. Refer to Spark Plug Wire Replacement .



8. Install the fender wheelhouse extension (1).
9. Install the front tire. Refer to Tire and Wheel Removal and Installation .
10. Lower the vehicle.

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

1. Remove the catalytic converter from the exhaust manifold. Refer to Catalytic Converter Replacement .
2. Remove the engine cover. Refer to Engine Cover Replacement .
3. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Removal .
4. Remove the exhaust manifold, bolts and exhaust manifold.
5. Clean all sealing surfaces.

Notice: Refer to Fastener Notice in the Preface section.




1. Install the exhaust manifold and bolts.

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. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Removal .
3. Install the catalytic converter to the exhaust manifold.
4. Install the engine cover. Refer to Engine Cover Replacement .

Exhaust Manifold Replacement - Right Side 6.6L