Exhaust Manifold Installation (Right Side)

EXHAUST MANIFOLD INSTALLATION (RIGHT SIDE)

IMPORTANT: Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may effect vehicle emissions and/or On-Board Diagnostic (OBD II) system performance.

The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material.
Do not reuse Exhaust Gas Recirculation (EGR) valve and pipe gaskets or seals during assembly. Install NEW gaskets and O-ring seal.

1. Apply a 5 mm (0.20 inch) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts.
Refer to Sealers, Adhesives, and Lubricants.





2. Install the exhaust manifold gasket and exhaust manifold.

NOTICE: Refer to Fastener Notice in Service Precautions.

3. Install the exhaust manifold bolts.
3.1. Tighten the exhaust manifold bolts first pass to 15 Nm (11 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
3.2. Tighten the exhaust manifold bolts final pass to 25 Nm (18 ft. lbs.). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.





5. Install the Air Injection Reaction (AIR) pipe (with check valve), NEW gasket and bolts.
^ Tighten the AIR pipe to exhaust manifold bolts to 25 Nm (18 ft. lbs.).





6. Install the AIR tubing and clamps.
7. Install the oxygen sensor into the intake manifold.
^ Tighten the oxygen sensor to 41 Nm (30 ft. lbs.).

8. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe.
9. Insert the EGR valve pipe into the intake manifold.
10. Start the EGR valve pipe to intake manifold bolt.
Do not tighten the bolt at this time.
11. Install the EGR valve pipe to cylinder head bolts.
Do not tighten the bolt at this time.





12. Install a NEW EGR valve pipe exhaust manifold gasket and bolts.
12.1. Tighten the EGR valve pipe to intake manifold bolt to 10 Nm (89 inch lbs.).
12.2. Tighten the EGR valve pipe to cylinder head bolts to 50 Nm (37 ft. lbs.).
12.3. Tighten the EGR valve pipe to exhaust manifold bolts to 25 Nm (18 ft. lbs.).





13. Install the EGR valve, a NEW gasket and bolts.
13.1. Tighten the EGR valve bolts first pass to 10 Nm (89 inch lbs.).
13.2. Tighten the EGR valve bolts final pass to 30 Nm (22 ft. lbs.).