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Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Right Exhaust Manifold Studs
    GM305693Courtesy of GENERAL MOTORS CORP.
  1. Install the exhaust manifold studs if removed.
    2. Fig 2: Right Exhaust Manifold Gasket
    GM910980Courtesy of GENERAL MOTORS CORP.
  2. Install the right exhaust manifold gasket (1).
  3. Install the right exhaust manifold (2).
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the right exhaust manifold studs (4) and the nuts (3).

    Tighten:  Tighten the studs and the nuts to 30 N.m (22 lb ft).

  5. Raise the vehicle.
    6. Fig 3: EGR Valve Inlet Adapter Pipe Bolt
    GM911025Courtesy of GENERAL MOTORS CORP.
  6. Install the exhaust gas recirculation (EGR) valve inlet adapter pipe bolt (1) to the right exhaust manifold.

    Tighten:  Tighten the bolt to 29 N.m (21 lb ft).

  7. Lower the vehicle.
    8. Fig 4: Right Exhaust Manifold Heat Shield
    GM911016Courtesy of GENERAL MOTORS CORP.
  8. Install the right exhaust manifold heat shield (1).
  9. Install the right exhaust manifold heat shield bolts (2).

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

    10. Fig 5: Right Engine Lift Bracket
    GM910986Courtesy of GENERAL MOTORS CORP.
  10. Install the right engine lift bracket (1).
  11. Install the right engine lift bracket bolt (2) and the nut (3).

    Tighten:  Tighten the bolt and the nut to 30 N.m (22 lb ft).

    12. Fig 6: Fuel Injector Sight Shield Bracket
    GM911011Courtesy of GENERAL MOTORS CORP.
  12. Install the fuel injector sight shield bracket (1).
  13. Install the fuel injector sight shield bracket nuts (2).

    Tighten:  Tighten the nuts to 30 N.m (22 lb ft).

  14. Install the right side spark plugs to cylinders 2, 4 and 6. Refer to Spark Plug Replacement in Engine Controls - 3.8L.
    15. Fig 7: HO2S Electrical Connector
    GM911055Courtesy of GENERAL MOTORS CORP.
  15. Install the HO2S (2) to the right exhaust manifold. Refer to Heated Oxygen Sensor Replacement - Position 1
  16. Install the HO2S electrical connector (1) to the engine sight shield bracket.
  17. Connect the HO2S electrical connector (1).
  18. Return the engine to the original position.
  19. Raise the vehicle.
    20. Fig 8: Right Exhaust Manifold & Catalytic Converter Pipe
    GM911163Courtesy of GENERAL MOTORS CORP.
  20. Install the catalytic converter pipe (3) to the right exhaust manifold.
  21. Install the catalytic converter pipe stud nuts (2) to the right exhaust manifold.

    Tighten:  Tighten the stud nuts to 35 N.m (26 lb ft).

  22. Lower the vehicle.
    23. Fig 9: Right Exhaust Crossover Pipe Studs
    GM911162Courtesy of GENERAL MOTORS CORP.
  23. Install the exhaust crossover pipe studs (3) to the right exhaust manifold.

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

    24. Fig 10: Right Exhaust Crossover Heat Shield
    GM910984Courtesy of GENERAL MOTORS CORP.
  24. Install the exhaust crossover heat shield (2).
  25. Install the exhaust crossover heat shield nuts (1).

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

  26. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Right and Engine Mount Strut Replacement - Left in Engine Mechanical - 3.8L.
  27. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L26) or Fuel Injector Sight Shield Replacement (L32) in Engine Mechanical - 3.8L.
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