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

Removal Procedure
  1. Disconnect the battery negative cable from the battery. Refer to Battery Cable Replacement in engine electrical.
  2. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Interior Trim.

    3. Object Number: 234451 Size: SH
  3. Remove the oil level indicator and tube on the right side exhaust manifold. Refer to Oil Level Indicator and Tube Replacement .

    4. Object Number: 173284 Size: SH
  4. Remove the EGR pipe from the left side exhaust manifold.
  5. Remove the spark plugs from the cylinder head. Refer to Spark Plug Replacement .
  6. Remove the exhaust pipe at the exhaust manifold. Refer to General Exhaust System Replacement in Engine Exhaust.

    7. Object Number: 65852 Size: SH
  7. Remove the heat shields and nuts.

    8. Object Number: 64527 Size: MH
  8. Remove the exhaust manifold and nuts.
  9. Clean and inspect the sealing surfaces on the cylinder head. Refer to Exhaust Manifold Clean and Inspect (without RPO K19) .
  10. Clean the threads on the exhaust manifold mounting studs.

Installation Procedure
  1. Install the exhaust manifold.

    2. Object Number: 64527 Size: MH

    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.

  2. Install the exhaust manifold nuts.

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

  3. Install the spark plug heat shields and nuts.

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

  4. Install the exhaust pipe to the exhaust manifold. Refer to General Exhaust System Replacement in Engine Exhaust.
  5. Install the spark plugs to the cylinder head. Refer to Spark Plug Replacement .

    6. Object Number: 173284 Size: SH
  6. Install the EGR inlet pipe (left side exhaust manifold).

    7. Object Number: 234451 Size: SH
  7. Install the oil level indicator and tube (right side exhaust manifold). Refer to Oil Level Indicator and Tube Replacement .
  8. Install the engine cover in the vehicle. Refer to Engine Cover Replacement in Interior Trim.
  9. Connect the negative battery cable to the battery. Refer to Battery Cable Replacement .