Chevrolet 10162002 Exhaust Manifold

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Clean all old gasket material from the mating surfaces on the cylinder head and manifold.

Allow the engine to cool completely before beginning this procedure.

1. Disconnect the negative battery cable. 2. Remove the air cleaner assembly, hot-air pipe, and hot-air shroud. 3. Remove the generator or air conditioning brackets where they attach to the exhaust manifold. 4. Disconnect the exhaust pipe where it connects to the exhaust manifold flange, using penetrating oil if needed. 5. Pry back the metal retainers from the bolt heads. 6. Remove each of the bolts securing the exhaust manifold. 7. Remove the manifold from above, noting that on some late models it may be necessary to disconnect the intermediate shaft of the steering column for better access.

Unbolt the crossover pipe where it joins the front manifold, noting that on later models, the crossover pipe heat shield must be removed for access.

Loosen the exhaust manifold mounting nuts a quarter turn at a time from the inside out until they can be removed by hand, then separate the manifold from the head.

Next, unplug the electrical connector from the oxygen sensor, then remove the drivebelt and alternator.

To facilitate removal, apply penetrating oil to the threads of all exhaust manifold and exhaust pipe fasteners and allow it to soak in.

Clean the mating surfaces, inspect for distortion and cracks, and check for warpage as previously described. Position the manifold with a new gasket, install the mounting nuts finger tight, and tighten them gradually from the middle outwards until all are torqued.