Installation Procedure

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 Chevrolet Tahoe, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Refer to FASTENER NOTICE .

Fig 1: View of Exhaust Manifold, Heat Shield, & Bolts

Courtesy of GENERAL MOTORS CORP.

Install the heat shield (2), and bolts (1) to the exhaust manifold (1), if necessary.
Tighten: Tighten the bolts to 9 N.m (80 lb in).

Fig 2: View of Exhaust Manifold, Gasket, & Bolts

Courtesy of GENERAL MOTORS CORP.

IMPORTANT:

Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance.
The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material.
Do not apply sealant to the first three threads of the bolt.

Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 or equivalent to the threads of the exhaust manifold bolts.
Install the exhaust manifold, NEW gasket and bolts.
Tighten:
1. Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
2. Tighten the exhaust manifold bolts a final pass to 25 N.m (18 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, and work toward the outside bolts.
Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.

Fig 3: View of EGR Pipe

Courtesy of GENERAL MOTORS CORP.

Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe.
Install the EGR pipe.
Install the EGR valve pipe bolts until snug.
Tighten:
1. Tighten the intake manifold bolt (1) to 10 N.m (89 lb in).
2. Tighten the cylinder head bolts (2) to 50 N.m (37 lb ft).
3. Tighten the exhaust manifold bolts (3) to 30 N.m (22 lb ft).
Install the spark plugs. Refer to SPARK PLUGS .
Install the ignition coils. Refer to IGNITION COILS .
Raise the vehicle.

Fig 4: Identifying Exhaust Manifold Pipe Nuts

Courtesy of GENERAL MOTORS CORP.

Install the exhaust manifold pipe nuts.
Tighten: Tighten the nuts to 50 N.m (37 lb ft).
Lower the vehicle.