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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1067 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST MANIFOLD REPLACEMENT - RIGHT SIDENOTES
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Exhaust Manifold Replacement - Right Side: Notes

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Notes
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2007 GMC Yukon XL, 2007 GMC Yukon, 2007 Chevrolet Tahoe, 2007 Chevrolet Suburban, and 2007 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Exhaust Manifold, Gasket & Catalytic Converter
    GM1708617Courtesy of GENERAL MOTORS CORP.
  1. Drain the cooling system, if equipped with rear air conditioning (A/C). Refer to Draining and Filling Cooling System .
  2. Remove the ignition coils. Refer to Ignition Coil Replacement .
  3. Remove the spark plugs. Refer to Spark Plug Replacement .
  4. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  5. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) .
  6. Remove the catalytic converter to exhaust manifold nuts. (1500 series shown, 2500 series similar).
  7. Lower the vehicle.
    8. Fig 2: View Of Radiator Surge Tank Outlet Hose, Clamp & Water Pump
    GM1697283Courtesy of GENERAL MOTORS CORP.
  8. If equipped with rear A/C perform the following steps, otherwise proceed to step 15.
  9. Reposition the radiator surge tank outlet hose clamp at the water pump (1).
  10. Remove the radiator surge tank outlet hose (2) from the water pump.
  11. Reposition the outlet hose out of the way.
    12. Fig 3: View Of Heater Inlet Hose, Clamp & Waterpump
    GM1697282Courtesy of GENERAL MOTORS CORP.
  12. Reposition the heater inlet hose clamp (1) at the water pump.
  13. Remove the heater inlet hose (2) from the water pump.
  14. Reposition the inlet hose out of the way.
    15. Fig 4: View Of Exhaust Manifold, Gasket & Bolts
    GM1708618Courtesy of GENERAL MOTORS CORP.
  15. Remove the exhaust manifold bolts and exhaust manifold.
  16. Remove and discard the exhaust manifold gasket.
  17. Remove the exhaust seal from the exhaust manifold.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.