GM Service Manual Online
For 1990-2009 cars
Makes 🢒 Chevrolet 🢒 2004 🢒 C-Series Medium Duty Truck C6/7/8 - Mexico 🢒 Engine 🢒 Engine Exhaust 🢒 Exhaust Manifold Replacement - Right Side

Removal Procedure

    Object Number: 742280 Size: SH
  1. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the exhaust manifold pipe nuts. (left side shown, right side similar).
  3. Remove the exhaust pipe seal.
  4. Allow the muffler pipe to hang.
  5. Lower the vehicle.

    6. Object Number: 470704 Size: SH

    Important: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged.

  6. Remove the spark plug wires from the spark plugs and ignition coils.
  7. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 8.1L.

    8. Object Number: 470708 Size: SH
  8. Remove the exhaust manifold heat shield nuts.
  9. Remove the exhaust manifold heat shield.

    10. Object Number: 470725 Size: SH
  10. Remove the exhaust manifold bolt and nuts.
  11. Remove the exhaust manifold and gasket. Discard the gasket.
  12. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection in Engine Mechanical - 8.1L.

Installation Procedure

    Object Number: 470725 Size: SH
  1. Install a NEW exhaust manifold gasket.
  2. Install the exhaust manifold.

    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.

  3. Install the exhaust manifold bolt and nuts.

    4. Tighten

        • Tighten the exhaust manifold bolt to 35 N·m (26 lb ft).
        • Tighten the exhaust manifold nuts to 16 N·m (12 lb ft).

    Object Number: 470708 Size: SH
  4. Install the exhaust manifold heat shield.
  5. Install the exhaust manifold heat shield nuts.

    6. Tighten
    Tighten the exhaust manifold heat shield nuts to 25 N·m (12 lb ft).

  6. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 8.1L.

    7. Object Number: 470704 Size: SH

    Important: Fully install the spark plug wire by pushing on the exposed end of the spark plug boot. Do not push the spark plug wire on to the spark plug by using the metal heat shield.

  7. Install the spark plug wires to the spark plugs and ignition coils.

    8. Object Number: 742280 Size: SH
  8. Raise and suitably support the vehicle with safety stands.
  9. Raise the muffler pipe into position.
  10. Install the exhaust pipe seal.
  11. Install the exhaust manifold pipe nuts. (left side shown, right side similar).

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

  12. Lower the vehicle.