Installation Procedure

Important:  To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and the bolts in place.

1. Sub-assemble the NEW gaskets, the spark plug wire shields, and the bolts to the exhaust manifold.
2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
3. Install the exhaust manifold. Refer to EXHAUST MANIFOLD INSTALLATION - RIGHT .
4. Install the AIR pipe to the exhaust manifold, if equipped. Refer to SECONDARY AIR INJECTION .
5. Install the catalytic converter assembly. Refer to Catalytic Converter Replacement (4.3L)  or Catalytic Converter Replacement (5.0L and 5.7L)  .
6. Install the starter. Refer to STARTER .
   Fig 1: Ensuring Exhaust Manifold Bolts Are Held In Place

   Courtesy of GENERAL MOTORS CORP.
7. Install the spark plugs.
   CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fastener requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
8. Install the spark plug wire support and bolts.

   Tighten 

   Tighten the spark plug wire support bolts to 12 N.m (106 in lbs).

9. Install the spark plug wires.
   Fig 2: Installing Wire Support & Bolts

   Courtesy of GENERAL MOTORS CORP.
10. Install the fender wheelhouse extension (1).
11. Install the front tire. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION .
12. Lower the vehicle.
    Fig 3: Installing Fender Wheelhouse Extension

    Courtesy of GENERAL MOTORS CORP.