How to Install an Exhaust Manifold Gasket on a 1995 Chevy 1500

Engine exhaust leaves the cylinder head through a manifold or header pipes.

The exhaust manifold and exhaust mating surface on the Chevrolet V8 cylinder heads are machined in such a way as to remove the need for exhaust manifold gaskets. However, over time the manifold and head surface can become corroded, preventing a proper seal. In these cases, it's best to either replace the head and manifold, or simply install some exhaust manifold gaskets in between the two.

Things You'll Need

• Socket set with long wrench
• Penetrating oil (optional)
• Rags
• Pry bar
• Manifold gaskets
• Mechanics gloves

Instructions

1. Wait for the engine to cool completely before loosening the exhaust manifold bolts with the socket set and long wrench. If there is any amount of corrosion or rust build up on the manifold or bolts, spray the bolts down with penetrating oil and wait 30 minutes before attempting to loosen them. Once the bolts are loosened 1/4- to 1/2-inch, wipe any excess penetrating oil off the engine and manifold with the rags before moving on to Step 2.

2. Insert the pry bar between the manifold and the engine and carefully pry the manifold away from the engine far enough to allow you to insert the manifold gaskets down in between the manifold and cylinder head. Choose the point where you pry carefully, so as not to crush or otherwise damage any other engine components, spark plugs, plug wires or the exhaust shields.

3. Tighten the bolts back down once the gaskets are in place. Start the engine and let it run until it reaches normal operating temperature. Shut the engine off and put your heat resistant mechanics gloves on.

4. Tighten the exhaust manifold bolts down again, using the socket set and long wrench. Use care not to touch the manifold, especially with bare skin--doing so can deliver a nasty third degree burn in seconds.

5. Repeat Steps 1 through 4 on the opposite side. Repeat the tightening cycle of torquing the bolts with the engine cold, then hot, more than once, if necessary. (Because metal expands when it's hot, when the engine heats up the exhaust manifold bolts actually become loose.)

Tips & Warnings

• When the engine is running, an exhaust leak from the manifold often sounds like an engine knock to an untrained ear. If you hear this sound, listen carefully to see if there is any sort of hiss noise preceding or directly following the knocking noise. If so, this is an exhaust leak, not a sign of internal engine damage.