Mechanics

CHEVY 2500 HD EXHAUST

2002 Chevrolet Silverado • V8 4WD Automatic • 284,000 miles

Enter your question. What is the torque settings for exhaust manifold bolts? 2002 Chevy Siverado, 2500 6.0 gas, 4 wheel drive.
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Jr viverette
January 2, 2011.



EXHAUST MANIFOLD REPLACEMENT - LEFT (4.8L, 5.3L & 6.0L ENGINES)

Removal Procedure

1. Raise and suitably support the vehicle.
2. Remove the exhaust manifold pipe nuts.
Fig. 13: Exhaust Manifold Pipe Nuts - Left (4.8L, 5.3L & 6.0L Engines)
Courtesy of GENERAL MOTORS CORP.
3. Lower the vehicle.
4. Remove the spark plugs.
5. Remove the exhaust manifold bolts, manifold, and gasket.
6. Discard the gasket.
Fig. 14: Exhaust Manifold Gasket - Left (4.8L, 5.3L & 6.0L Engines)
Courtesy of GENERAL MOTORS CORP.
7. Remove the heat shield bolts (3), and shield (2) from the exhaust manifold (1), if necessary.
Fig. 15: Exhaust Manifold Heat Shield - Left (4.8L, 5.3L & 6.0L Engines)
Courtesy of GENERAL MOTORS CORP.
8. Clean and inspect the exhaust manifold.
Installation Procedure

1. Install the heat shield (2), and bolts (3) to the exhaust manifold (1), if necessary. Tighten the
exhaust manifold heat shield bolts to 9 N.M (68 lb in).
Important: ? Tighten the exhaust manifold bolts as specified in the service procedure. Improperly
installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or
On-Board Diagnostics (OBD) II system performance.
? The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or
threadlocking material.
Important: Do not apply sealant to the first three threads of the bolt.
2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N United States 12345493 GM P/N
Canada 10953488, or equivalent to the threads of the exhaust manifold bolts.
3. Install the exhaust manifold, NEW gasket and bolts.
3.1. Tighten the exhaust manifold bolts a first pass to 15 N.M (11 lb ft). Tighten the
exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side,
and work toward the outside bolts.
3.2. Tighten the exhaust manifold bolts a first pass to 25 N.M (18 lb ft). Tighten the
exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side,
and work toward the outside bolts.
4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of
the left cylinder head.
5. Install the spark plugs.
6. Raise the vehicle.
7. Install the exhaust manifold pipe nuts. Tighten the exhaust manifold pipe nuts to 50 N.M (37 lb
ft).
8. Lower the vehicle.
EXHAUST MANIFOLD REPLACEMENT - RIGHT (4.8L, 5.3L & 6.0L ENGINES)

1. Raise and suitably support the vehicle.
2. Remove the exhaust manifold pipe nuts.
Fig. 29: Exhaust Manifold Pipe Nuts
Courtesy of GENERAL MOTORS CORP.
3. Lower the vehicle.
4. Remove the spark plugs.
5. Remove the bolts (1, 2, 3) attaching the exhaust gas recirculation (EGR) valve pipe to the
following, if equipped: ? Intake manifold
? Cylinder head
? Exhaust manifold
6. Remove the EGR valve pipe and gaskets, if equipped. With mild force, pull the EGR valve
pipe from the intake manifold.
Fig. 30: EGR Valve Pipe & Gaskets (4.8L, 5.3L & 6.0L Engines)
Courtesy of GENERAL MOTORS CORP.
7. Remove the O-ring seal from the EGR valve pipe, if equipped.
8. Discard the gasket and the O-ring seal, if equipped.
9. Remove the exhaust manifold bolts, manifold, and gasket.
Fig. 31: Exhaust Manifold & Gasket (4.8L, 5.3L & 6.0L Engines)
Courtesy of GENERAL MOTORS CORP.
10. Discard the gasket.
11. Remove the heat shield bolts (1), and shield (2) from the exhaust manifold (1), if necessary.
Fig. 32: Exhaust Manifold Heat Shield (4.8L, 5.3L & 6.0L Engines)
Courtesy of GENERAL MOTORS CORP.
12. Clean and inspect the exhaust manifold.
Installation Procedure

1. Install the heat shield (2), and bolts (1) to the exhaust manifold (1), if necessary. Tighten the
exhaust manifold heat shield bolts to 9 N.M (80 lb in).
Important: ? Tighten the exhaust manifold bolts as specified in the service procedure. Improperly
installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or
On-Board Diagnostics (OBD) II system performance.
? The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or
threadlocking material.
Important: Do not apply sealant to the first three threads of the bolt.
2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N United States 12345493, GM P/N
Canada 10953488, or equivalent to the threads of the exhaust manifold bolts.
3. Install the exhaust manifold, NEW gasket and bolts.
3.1. Tighten the exhaust manifold bolts a first pass to 15 N.M (11 lb ft). Tighten the
exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side,
and work toward the outside bolts.
3.2. Tighten the exhaust manifold bolts a final pass to 25 N.M (18 lb ft). Tighten the
exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side,
and work toward the outside bolts.
4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of
the right cylinder head.
5. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the
EGR valve pipe, if equipped.
6. Install the EGR pipe, if equipped.
7. Install the EGR valve pipe bolts until snug, if equipped.
7.1. Tighten the EGR valve pipe to intake manifold bolt (1) to 10 N.M (89 lb in).
7.2. Tighten the EGR valve pipe to cylinder head bolts (2) to 50 N.M (37 lb ft).
7.3. Tighten the EGR valve pipe to exhaust manifold bolts (3) to 30 N.M (22 lb ft).
8. Install the spark plugs.
9. Raise the vehicle.
10. Install the exhaust manifold pipe nuts. Tighten the exhaust manifold pipe nuts to 50 N.M (37 lb
ft).
11. Lower the vehicle.


Merlin2021
Jan 2, 2011.
Thanks merlin2021, just what I needed. Have had a time with this one. Right side had three broken bolts left has two. Had to weld nuts on end of broken bolts to get out and one of the three broke coming out one thread below the head service. Mange to weld nut onto broken stud and after three attempts got out. I called a friend who had a Hanes manual and he said the manual said to torgue to 132 lbs first pass and then to 18 on second. Made no sense but tried anyway. Set torgue wrench to 100 lbs and broke one of the new manifold bolts. Had to remove manifold again and weld out new bolt. Then I said time to get some more info. The procedures here make more sense and 11 and 18 sound better. Hope I have not stretched bolts to bad. I have to get back together today, as this is my daily driver and no parts available until tomorrow. Will also have to use one of the old exhaust bolts now. Chevy dealer only had 6 bolts in stock on Friday and I only planned to do the right side this weekend and wait for more parts to do the left. Again thanks and sorry for the rambling.


Tiny
Jr viverette
Jan 2, 2011.
Your welcome!


Merlin2021
Jan 2, 2011.
I've had the same problem before. After many bloody knuckles, snapped bolts and cursing like a drunken sailor, I found these bracket/clamps are just the ticket. Easy to install and they just plain work. I've had 2 friends with the same issues on a Chevy 6.0 liter and a GMC 5.3 liter and after hearing my horror stories, they tried them too. See what you think... http://www.kralautoparts.com.


Tiny
Goose19
May 13, 2013.