GM 10087655 Exhaust Manifold

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If the engine has been removed from the car, disregard the following steps which do not apply. First, if the vehicle is equipped with air conditioning, carefully examine the routing of the A/C hoses and the mounting of the compressor, as it may be possible to remove the exhaust manifolds without disconnecting the A/C system; if in doubt, consult a certified dealer or refrigeration specialist to have the system depressurized, and do not disconnect the A/C hoses while under pressure. Next, disconnect the negative battery cable and the carburetor hot air pipe routed from the right exhaust manifold to the air cleaner. Mark each spark plug wire with coded tape before removing them, ensuring not to mix up the order. Remove the air cleaner and the PULSAIR bracket bolt from the right rocker cover, along with the system's plumbing from both exhaust manifolds, and any remaining hoses. Raise the front of the car and support it on jackstands, then disconnect the left exhaust pipe from the exhaust manifold, using penetrating oil if the bolts are tight. The EFE valve, mounted between the right exhaust manifold and exhaust pipe, can be disconnected by tightening the upper manifold flange nuts until the bolts break, allowing the exhaust pipe to be removed. If bolt locking strips are present, use a screwdriver to pry them away from the exhaust manifold bolt heads for easier access. Remove the exhaust manifold end bolts first, followed by the center bolts, and lift the manifold away from the engine. Before installing the exhaust manifolds, clean the mating surfaces on the cylinder heads and exhaust manifolds, ensuring all leftover gasket material is removed. Place new gaskets into position on the cylinder head, using a thin film of sealer to hold them in place, then install the manifold and tighten the bolts gradually in sequence until they are all torqued to specifications. Reinstall the remaining components in reverse order of removal, using new exhaust pipe bolts when connecting the right exhaust manifold to the exhaust pipe. For later V6 models with slip joints in the exhaust crossover pipe, take care to avoid damage when tightening the nuts; insert the right side of the pipe into its manifold and install the nuts finger tight, then insert the left side and secure the lower nut before tightening the upper nut and both right side nuts. Finally, start the engine and check for exhaust leaks at the manifold and exhaust pipe connections.

If the engine has been removed from the car, disregard the following steps which do not apply. First, if the vehicle is equipped with air conditioning, carefully examine the routing of the A/C hoses and the mounting of the compressor, as it may be possible to remove the exhaust manifolds without disconnecting the A/C system; if in doubt, consult a certified dealer or refrigeration specialist to have the system depressurized, and do not disconnect the A/C hoses while under pressure. Next, disconnect the negative battery cable and the carburetor hot air pipe routed from the right exhaust manifold to the air cleaner. Mark each spark plug wire with coded tape before removing them, ensuring not to mix up the order. Remove the air cleaner and the PULSAIR bracket bolt from the right rocker cover, along with the system's plumbing from both exhaust manifolds, and any remaining hoses. Raise the front of the car and support it on jackstands, then disconnect the left exhaust pipe from the exhaust manifold, using penetrating oil if the bolts are tight. The EFE valve, mounted between the right exhaust manifold and exhaust pipe, can be disconnected by tightening the upper manifold flange nuts until the bolts break, allowing the exhaust pipe to be removed. If bolt locking strips are present, use a screwdriver to pry them away from the exhaust manifold bolt heads for easier access. Remove the exhaust manifold end bolts first, followed by the center bolts, and lift the manifold away from the engine. Before installing the exhaust manifolds, clean the mating surfaces on the cylinder heads and exhaust manifolds, ensuring all leftover gasket material is removed. Place new gaskets into position on the cylinder head, using a thin film of sealer to hold them in place, then install the manifold and tighten the bolts gradually in sequence until they are all torqued to specifications. Reinstall the remaining components in reverse order of removal, using new exhaust pipe bolts when connecting the right exhaust manifold to the exhaust pipe. For later V6 models with slip joints in the exhaust crossover pipe, take care to avoid damage when tightening the nuts; insert the right side of the pipe into its manifold and install the nuts finger tight, then insert the left side and secure the lower nut before tightening the upper nut and both right side nuts. Finally, start the engine and check for exhaust leaks at the manifold and exhaust pipe connections.

If the car has A/C be very careful with the A/C hoses and the position of the compressor, as it is many times possible to take off the exhaust manifold without affecting the A/C system, but if there is any doubt take the car to a GM dealer or a qualified mechanic and take the pressure off the system and do not disconnect any A/C hoses with pressure on them. First, eliminate the air cleaner and the carburetor pre-heat tube if present, second, eliminate the front engine strut that is installed between the radiator support and the cylinder head. First, unbolt the engine oil dipstick tube on the left of the exhaust manifold, and the exhaust sensor on the side of the exhaust manifold. Next, remove the A/C compressor mounting bracket provided at the centre of the exhaust manifold as well. That identifies the positions of the four spark plug wires, removes them and suspends them at the side to afford room for working. Remove the exhaust pipe nut connecting to the exhaust manifold and suspend it with wire to the frame. First, take out the end bolts of the exhaust manifold, then the center ones, after that, exhaust manifold as well as gasket. As a prior to fitting a new exhaust manifold clean the surfaces on the cylinder head and manifold that comes in contact with the gasket where there should be no leftover gasket material. Install a new exhaust manifold gasket on the cylinder head of the engine and fit the manifold in position, tightening the manifold nuts to only as far as was comfortable with your fingers. Turn the manifold mounting bolts slowly in a progressive manner until all get to the required torque. Last of all replace all components in reverse order with new gaskets where required cranking the engine and checking for exhaust leaks at the joint between the manifold and cylinder head, and the manifold and exhaust pipe.

After disconnecting the exhaust pipe and other components, the next step involves bending back any locking tabs on the mounting nuts, soaking them with solvent, and then loosening and removing them. This allows for the removal of the manifold and seal. It's also crucial to ensure that the block's surface is thoroughly cleaned.

Tighten the manifold mounting bolts gradually in sequence until all are torqued to specifications.

If the engine has been removed from the car, disregard the following steps which do not apply.

Disconnect the exhaust pipe from the exhaust manifold, hanging it from the frame using wire.

Install the manifold, torque-tightening the center bolts first and then the end bolts.

1. Disconnect the battery. 2. Remove the air cleaner assembly. 3. Disconnect the hot-air pipe to the manifold. 4. Remove the hot-air shroud around the manifold. 5. Raise the car and support it firmly on jack stands. 6. Bend back the metal retainers around each manifold bolt head. 7. Remove each of the bolts. 8. Disconnect the exhaust pipe from the manifold, using penetrating oil if the fasteners are 'frozen' in place. 9. Remove the flywheel lower cover and the starter brace, wiring, and starter. 10. Remove the exhaust manifold from under the car.