Installation Procedure

WARNING: This page is about a different car, the 2003 Buick Regal and 2003 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.

Install the exhaust manifold studs if removed.

Fig 1: Installing Exhaust Manifold Studs
Courtesy of GENERAL MOTORS CORP.
If replacing the right exhaust manifold, install the heated oxygen (HO2S) sensor to the right exhaust manifold. Refer to HEATED OXYGEN SENSOR in Removal & Installation.
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 Right Exhaust Manifold, Nuts & Bolts
Courtesy of GENERAL MOTORS CORP.
Install the fuel injector sight shield bracket.

Fig 5: Installing Fuel Injector Sight Shield Bracket & Nuts
Courtesy of GENERAL MOTORS CORP.
Install the fuel injector sight shield bracket nuts.
Tighten

Tighten the nuts to 30 N.m (22 lb ft).
Install the right engine lift bracket.

Fig 6: Installing Right Engine Lift Bracket, Nut & Bolt
Courtesy of GENERAL MOTORS CORP.
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 Self-Diagnostics - 3.8L.
Install the heated oxygen (HO2S) sensor electrical connector (4) to the engine sight shield bracket (1).

Fig 7: Installing Heated Oxygen (HO2S) Sensor Electrical Connector
Courtesy of GENERAL MOTORS CORP.
Connect the heated oxygen (HO2S) sensor electrical connector (4).
Return the engine to the original position.
Raise the vehicle.
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 & Bolt
Courtesy of GENERAL MOTORS CORP.
Install the catalytic converter pipe to the right exhaust manifold.

Fig 9: Installing Catalytic Converter Pipe & Nuts
Courtesy of GENERAL MOTORS CORP.
Install the catalytic converter pipe stud nuts to the right exhaust manifold.
Tighten

Tighten the stud nuts to 35 N.m (26 lb ft).
Lower the vehicle.
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
Courtesy of GENERAL MOTORS CORP.
Install the exhaust crossover heat shield.

Fig 11: Installing Exhaust Crossover Heat Shield & Nuts
Courtesy of GENERAL MOTORS CORP.
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.
Install the cross vehicle brace. Refer to BRACE REPLACEMENT - CROSS VEHICLE in Body Front End.