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Exhaust Manifold Installation - Right (With A.I.R.)

WARNING: This page is about a different car, the 2004 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing/Installing Right Exhaust Manifold
    GM683928Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  1. Install the exhaust manifold studs.

    Tighten:  Tighten the exhaust manifold studs to 10 N.m (89 lb in).

    2. Fig 2: Right Exhaust Manifold
    GM683924Courtesy of GENERAL MOTORS CORP.
  2. Install the exhaust manifold gasket.
  3. Install the exhaust manifold.
  4. Install the exhaust manifold bolts and nuts.

    Tighten:  Tighten the exhaust manifold bolts and nuts to 30 N.m (22 lb ft).

  5. Install the right side spark plugs.

    Tighten: 

    • Tighten the spark plugs to 27 N.m (20 lb ft) when installing the spark plugs in to a new cylinder head.
    • Tighten the spark plugs to 15 N.m (13 lb ft) when re-installing the spark plugs after initial installation.

    6. Fig 3: Fuel Injector Sight Shield Cover Bracket
    GM347473Courtesy of GENERAL MOTORS CORP.
  6. Install the fuel injector sight shield cover bracket.
  7. Install the fuel injector sight shield cover bracket nuts.

    Tighten:  Tighten the fuel injector sight shield bracket nuts to 30 N.m (22 lb ft).

    8. Fig 4: Removing/Installing Right Engine Lift Hook Bracket
    GM154526Courtesy of GENERAL MOTORS CORP.
  8. Install the right engine lift hook.
  9. Install the right engine lift hook nut and bolt.

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

    10. Fig 5: Secondary Air Injection Assembly
    GM1403432Courtesy of GENERAL MOTORS CORP.
  10. If necessary, install the secondary air pipe (644), gasket (647), and bolts (646) and assemble the injection pump (636) onto bracket (648).

    Tighten:  Tighten the secondary air injection pump pipe bolts to 10 N.m (89 lb in).

  11. Install gasket (645), secondary air injection pump assembly and nuts (641) onto the engine.

    Tighten:  Tighten the secondary air injection pump assembly nuts to 10 N.m (89 lb in).

  12. Install the secondary air injection pump assembly mounting bolts (637, 649).

    Tighten:  Tighten the secondary air injection pump assembly mounting bolts to 10 N.m (89 lb in).

    13. Fig 6: Secondary Air Injection Pipe
    GM1403429Courtesy of GENERAL MOTORS CORP.
  13. Loosen the hose clamp and install the secondary air injection pipe (640) onto the valve and reinstall the hose clamp.
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