Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.

Install the exhaust manifold studs if removed.
If replacing the right exhaust manifold, install the heated oxygen (HO2S) sensor to the right exhaust manifold. Refer to HEATED OXYGEN SENSOR in Engine Controls - 3.8L.

Fig 1: Installing Exhaust Manifold Studs
Courtesy of GENERAL MOTORS CORP.
Install the lower right exhaust manifold heat shield.

Fig 2: Installing Lower Right Exhaust Manifold Heat Shield
Courtesy of GENERAL MOTORS CORP.
Install the upper right exhaust manifold heat shield.

Fig 3: Installing Upper Right Exhaust Manifold Heat Shield
Courtesy of GENERAL MOTORS CORP.
Install the new right exhaust manifold gasket.
Install the right exhaust manifold.
NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
Install the right exhaust manifold bolts and the nuts.
Tighten

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

Fig 4: Installing Gasket And Right Exhaust Manifold
Courtesy of GENERAL MOTORS CORP.
Install the fuel injector sight shield bracket.
Install the fuel injector sight shield bracket nuts.
Tighten

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

Fig 5: Installing Fuel Injector Sight Shield Bracket And Nuts
Courtesy of GENERAL MOTORS CORP.
Install the right engine lift bracket.
Install the right engine lift bracket bolt and the nut.
Tighten

Tighten the bolt and the nut to 30 N.m (22 lb ft).
Install the right side spark plugs to cylinders 2, 4 and 6. Refer to SPARK PLUGS in Engine Controls - 3.8L.

Fig 6: Installing Right Engine Lift Bracket With Bolt And Nut
Courtesy of GENERAL MOTORS CORP.
Install the heated oxygen (HO2S) sensor electrical connector (4) to the engine sight shield bracket (1).
Connect the heated oxygen (HO2S) sensor electrical connector (4).
Return the engine to the original position.
Raise the vehicle.

Fig 7: Connecting Heated Oxygen Sensor Electrical Connector
Courtesy of GENERAL MOTORS CORP.
Install the EGR valve inlet adapter pipe to the right exhaust manifold.
Tighten

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

Fig 8: Installing EGR Valve Inlet Adapter Pipe To Right Exhaust Manifold
Courtesy of GENERAL MOTORS CORP.
Install the catalytic converter pipe to the right exhaust manifold.
Install the catalytic converter pipe stud nuts to the right exhaust manifold.
Tighten

Tighten the stud nuts to 32 N.m (24 lb ft).
Lower the vehicle.

Fig 9: Installing Catalytic Converter Pipe To Right Exhaust Manifold
Courtesy of GENERAL MOTORS CORP.
Install the exhaust crossover bolts to the right exhaust manifold.
Tighten

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

Fig 10: Installing Exhaust Crossover Bolts To Right Exhaust Manifold
Courtesy of GENERAL MOTORS CORP.
Install the exhaust crossover heat shield.
Install the exhaust crossover heat shield nuts.
Tighten

Tighten the nuts to 20 N.m (15 lb ft).
Install the engine mount struts. Refer to ENGINE MOUNT STRUT REPLACEMENT - RIGHT and ENGINE MOUNT STRUT REPLACEMENT - LEFT in Engine Mechanical - 3.8L.
Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67) in Engine Mechanical - 3.8L.

Fig 11: Installing Exhaust Crossover Heat Shield And Nuts
Courtesy of GENERAL MOTORS CORP.