Exhaust Manifold Replacement - Right Side

Exhaust Manifold Replacement - Right Side

Removal Procedure




1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement).
2. Remove the generator. Refer to Generator Replacement (Service and Repair).
3. Remove the ignition coil. Refer to Ignition Coil Replacement (Service and Repair).
4. Disconnect the engine harness electrical connector (4) from the heated oxygen sensor (HO2S).





Important: The HO2S uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.


5. Remove the HO2S.
6. Disconnect the heater hose from the heater pipes.
7. Remove the nuts holding the heater pipes onto the throttle body.
8. Position the heater pipes out of the way.




9. Remove the exhaust crossover pipe heat shield bolts (1) and shield (2).




10. Remove the exhaust crossover pipe (2) to exhaust manifold nuts (1).
11. Remove the catalytic converter. Refer to Catalytic Converter Replacement (Service and Repair).




12. Remove the exhaust manifold heat shield bolts.
13. Remove the exhaust manifold heat shield.




14. Remove the exhaust manifold bolts.
15. Remove the exhaust manifold.
16. Remove the exhaust manifold gasket.

Installation Procedure




1. Position a NEW exhaust manifold gasket to the cylinder head.
2. Install the exhaust manifold.

Notice: Refer to Fastener Notice (Fastener Notice).

3. Install the exhaust manifold bolts.

Tighten the bolts to 20 N.m (15 lb ft).




4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts.

Tighten the bolts to 10 N.m (89 lb in).

6. Install the catalytic converter. Refer to Catalytic Converter Replacement (Service and Repair).




7. Install the exhaust crossover pipe (2) to exhaust manifold nuts (1).

Tighten the nuts to 20 N.m (15 lb ft).




8. Install the exhaust crossover pipe heat shield (2) and bolts (1).

Tighten the bolts to 10 N.m (89 lb in).

9. Position the heater pipes back to the original position.
10. Install the nut holding the heater pipes onto the throttle body.
11. Connect the heater hoses to the heater pipes.





Important: Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound such as GM P/N 5613695 or equivalent.


12. Install the HO2S.

Tighten the sensor to 42 N.m (31 lb ft).




13. Connect the engine harness electrical connector (4) to the HO2S.
14. Install the ignition coil. Refer to Ignition Coil Replacement (Service and Repair).
15. Install the generator. Refer to Generator Replacement (Service and Repair).
16. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement).