Exhaust Manifold Replacement - Left Side 3.8L

1. Turn the ignition OFF.
2. Remove the left and the right torque strut bolts at the engine strut bracket.



3. Remove the exhaust crossover pipe to left bank exhaust manifold nuts (5).
4. Remove the oil lever indicator and tube. Refer to Oil Level Indicator and Tube Replacement .



5. Remove the exhaust manifold heat shield bolts.
6. Remove the exhaust manifold heat shield.



7. Remove the exhaust manifold bolts.
8. Remove the exhaust manifold.
9. Remove and discard the exhaust manifold gasket.
10. Clean and inspect the exhaust manifold and the sealing surfaces. Refer to Exhaust Manifold Cleaning and Inspection - Left Side .

1. Install the NEW exhaust manifold gasket.
2. Install the exhaust manifold.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the exhaust manifold bolts.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).




4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

6. Install the oil lever indicator and tube. Refer to Oil Level Indicator and Tube Replacement .



7. Install the exhaust crossover pipe to left bank exhaust manifold nuts (5). Refer to Exhaust Crossover Pipe Replacement .
8. Install the left and the right torque strut at the engine. Secure with the strut bolts.

Tighten
Tighten the bolts to 48 N·m (35 lb ft).

Exhaust Manifold Replacement - Left Side RPO LY7

1. Remove the left and right engine mount struts. Refer to Engine Mount Strut Replacement - Left Side Exhaust Manifold Replacement - Right Side and Engine Mount Strut Replacement - Right Side Engine Mount Strut Replacement - Right Side .
2. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement .



3. Remove the exhaust crossover pipe to left exhaust manifold nuts (5).



4. Remove the exhaust manifold heat shield bolts.
5. Remove the exhaust manifold heat shield.



6. Remove the exhaust manifold bolts.
7. Remove the exhaust manifold.
8. Remove and discard the exhaust manifold gasket.
9. Clean and inspect the exhaust manifold sealing surfaces.

1. Install one exhaust manifold bolt through a bolt hole in the manifold.
2. Install the NEW exhaust manifold gasket onto the bolt.
3. Position the exhaust manifold to the cylinder head.
4. Install the exhaust manifold using the one installed bolt until snug.

Notice: Refer to Fastener Notice in the Preface section.

5. Install the remaining exhaust manifold bolts.

Tighten
Tighten the bolts to 30 N·m (22 lb ft).




6. Install the exhaust manifold heat shield.
7. Install the exhaust manifold heat shield bolts.

Tighten
Tighten the bolts to 10 N·m (89 lb in).




8. Install the exhaust crossover pipe to exhaust manifold nuts (5).

Tighten
Tighten the nuts to 25 N·m (18 lb ft).




9. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement .
10. Install the left and right engine mount struts. Refer to Engine Mount Strut Replacement - Left Side Exhaust Manifold Replacement - Right Side and Engine Mount Strut Replacement - Right Side Engine Mount Strut Replacement - Right Side .
11. Inspect for exhaust leaks.

Exhaust Manifold Replacement - Left Side RPO LS4

1. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
2. Remove the exhaust crossover pipe heat shield in order to access the cross pipe to the exhaust manifold nuts.
3. Remove the exhaust crossover pipe nuts from the left exhaust manifold.
4. Remove the left side spark plugs. Refer to Spark Plug Replacement .
5. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .



6. Remove the exhaust manifold heat shield bolts (604).
7. Remove the exhaust manifold heat shield (603).
8. Remove the heater hose retainer bolts in order to be able to remove the manifold.



9. Remove the exhaust manifold bolts.
10. Remove the exhaust manifold.
11. Remove and discard the exhaust manifold gasket.

Important: 

1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the threads of the exhaust manifold bolts.

Notice: Refer to Fastener Notice in the Preface section.

2. Install a NEW exhaust manifold gasket, the exhaust manifold and bolts.

Tighten

•	Tighten the bolts a first pass to 15 N·m (11 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side to side, and work toward the outside.

•	Tighten the bolts a final pass to 20 N·m (15 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side to side, and work toward the outside.

3. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.



4. Install the exhaust manifold heat shield (603).
5. Install the exhaust manifold heat shield bolts (604).

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

6. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
7. Install the left side spark plugs. Refer to Spark Plug Replacement .



8. Install the exhaust crossover pipe nuts from the left exhaust manifold.

Tighten
Tighten the nuts to 25 N·m (18 lb ft).

9. Install the exhaust crossover pipe heat shield.
10. Install the heater pipe retainer bolts.

Tighten
Tighten the bolts to 16 N·m (12 lb ft).

11. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .