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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1028 (Engine Exhaust System) >> Repair Instructions >> Exhaust Manifold Replacement - Right (6.6L (LLY) Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the exhaust manifold gasket to the cylinder head.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    Fig 1: View Of Exhaust Manifold (6.6L (LLY) Engine)
    GM1336108Courtesy of GENERAL MOTORS CORP.
  2. Install the bolt for the oil level indicator tube bracket.

    Tighten:  Tighten the bolt to 21 N.m (15 lb ft).

  3. Install the exhaust manifold.
  4. Install the exhaust manifold bolts/nuts.
    5. Fig 2: Exhaust Manifold Bolt And Nut Loosening Sequence (6.6L (LLY) Engine)
    GM1336107Courtesy of GENERAL MOTORS CORP.
  5. Using the sequence shown, properly tighten the exhaust manifold bolts.

    Tighten:  Tighten the bolt/nuts to 38 N.m (28 lb ft).

    6. Fig 3: Exhaust Manifold Heat Shield (6.6L (LLY) Engine)
    GM1336106Courtesy of GENERAL MOTORS CORP.
  6. Install the exhaust manifold heat shield.
  7. Install the exhaust manifold heat shield bolts.

    Tighten:  Tighten the bolts to 8 N.m (71 lb in).

    8. Fig 4: Exhaust Pipe To The Exhaust Manifold Bolts (6.6L (LLY) Engine)
    GM1334834Courtesy of GENERAL MOTORS CORP.
  8. Install the exhaust pipe gasket. Align the tab on the gasket to face outward.
  9. Install the exhaust pipe bolts (3, 4, and 5).

    Tighten:  Tighten the bolts to 53 N.m (39 lb ft).

  10. Install the wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  11. Lower the vehicle.
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