Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Install the a NEW exhaust manifold gasket.

Fig 1: View Of Exhaust Manifold Assembly (8.1L Engine)
Courtesy of GENERAL MOTORS CORP.
Install the exhaust manifold.
NOTE: Refer to Fastener Notice in Cautions and Notices.
Install the exhaust manifold bolt and nuts.
Tighten:
- Tighten the bolt to 35 N.m (26 lb ft).
- Tighten the nuts to 16 N.m (12 lb ft).
Raise and suitably support the vehicle with safety stands.

Fig 2: Exhaust Manifold Heat Shield (8.1L Engine)

Courtesy of GENERAL MOTORS CORP.

Install the exhaust manifold heat shield.
Install the exhaust manifold heat shield bolts and nuts.
Tighten: Tighten the bolts/nuts to 25 N.m (18 lb ft).
Lower the vehicle.
Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 8.1L.

Fig 3: View Of Spark Plug Wires (Right)

Courtesy of GENERAL MOTORS CORP.

IMPORTANT: Fully install the spark plug wires by pushing on the exposed end of the spark plug boot. Do not push the spark plug wire on to the spark plug by using the metal heat shield.

Install the spark plug wires to the spark plugs and ignition coils.
Install the oil level indicator. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical - 8.1L.
Install the wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.