2002 Chevy Silverado 2500 hd exhaust

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.

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