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Exhaust Manifold Installation (With Secondary Air Injection)

WARNING: This page is about a different car, the 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Exhaust Manifold Studs
    GM412550Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  1. Install new exhaust manifold studs and tighten to 10 N.m (89 lb in).
    2. Fig 2: View of Secondary Air Injection Pipe Assembly Bolts
    GM2179170Courtesy of GENERAL MOTORS CORP.
  2. Install the secondary air injection pipe assembly (1).
  3. Install the secondary air injection pipe assembly bolts (2) and tighten to 10 N.m (89 lb in).
    4. Fig 3: View of Exhaust Manifold to Cylinder Head Retaining Nuts
    GM2179169Courtesy of GENERAL MOTORS CORP.
  4. Install the exhaust manifold gasket (2).
  5. Install the exhaust manifold (1) to the cylinder head.
  6. Install NEW exhaust manifold to cylinder head retaining nuts (3) finger tight.
    7. Fig 4: Exhaust Manifold Brace And Bolts
    GM2179168Courtesy of GENERAL MOTORS CORP.
  7. Install the exhaust manifold brace (1) and bolts (2). Tighten the bolts to 58 N.m (43 lb ft).
    8. Fig 5: Exhaust Manifold Bolt Tightening Sequence
    GM1340643Courtesy of GENERAL MOTORS CORP.
  8. Tighten the NEW exhaust manifold to cylinder head retaining nuts two passes in sequence. Tighten the nuts to 14 N.m (124 lb in).
    9. Fig 6: View of Oxygen Sensor
    GM2179167Courtesy of GENERAL MOTORS CORP.
  9. Coat the threads of the oxygen sensor (1) with antiseize. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  10. Install the oxygen sensor and tighten to 42 N.m (31 lb ft).
    11. Fig 7: View Of Block Heater
    GM825111Courtesy of GENERAL MOTORS CORP.
  11. Install the block heater, if equipped. Tighten the block heater to 10 N.m (89 lb in).
    12. Fig 8: View of Exhaust Manifold Heat Shield
    GM2179166Courtesy of GENERAL MOTORS CORP.
  12. Install the exhaust manifold heat shield (2).
  13. Install the exhaust manifold heat shield bolt (1) and tighten to 25 N.m (18 lb ft).
    14. Fig 9: View of Secondary Air Injection Studs
    GM2179164Courtesy of GENERAL MOTORS CORP.
  14. Install the secondary air injection studs (3 and 4) and tighten to 10 N.m (89 lb in).
  15. Install the secondary air injection valve assembly (1) with a NEW gasket (2).
    16. Fig 10: View of Exhaust Manifold and Secondary Air Injection Bolts and Nuts
    GM2179163Courtesy of GENERAL MOTORS CORP.
  16. Install the secondary air injection bolts (2) and nuts (1).
    1. Tighten the secondary air injection assembly and exhaust manifold heat shield bolts to 22 N.m (16 lb ft)
    2. Tighten the secondary air injection assembly to pipe assembly bolts to 10 N.m (89 lb in)
    3. Tighten the secondary air injection assembly nuts to 22 N.m (16 lb ft)
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