Exhaust Manifold Installation - Right (with RPO NC1 or NF7)

Important:  Align the threaded hole in the engine block with the hole labeled R (1) on the right coolant heater.

1. Install the right engine coolant heater.
   Fig 1: Identifying Right Coolant Heater Markings

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   CAUTION: Refer to in FASTENER NOTICE .
2. Install the right engine coolant heater bolt.

   Tighten 

   Tighten the right coolant heater bolt to 9 N.m (80 in lbs).

   Fig 2: Installing Right Engine Coolant Heater

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3. Install the knock sensor.

   Tighten 

   Tighten the knock sensor to 15 N.m (11 ft lbs).

   Fig 3: Installing Knock Sensor

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4. Install the wiring harness bracket.
5. Install the wiring harness bracket bolt.

   Tighten 

   Tighten the wiring harness bracket bolt to 25 N.m (18 ft lbs).

   Fig 4: Installing Wiring Harness Bracket

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6. Install the oil pressure switch.

   Tighten 

   Tighten the oil pressure switch to 10 N.m (89 in lbs).

   Fig 5: Installing Oil Pressure Switch

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7. Install the ECT sensor.

   Tighten 

   Tighten the ECT sensor to 20 N.m (15 ft lbs).

   Fig 6: Installing ECT Sensor

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8. Install the engine wiring harness.
9. Connect the engine wiring harness to the ECT sensor.
   Fig 7: Connecting Engine Wiring Harness To ECT Sensor

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10. Install the engine wiring harness to the lower crankcase.
    Fig 8: Installing Engine Wiring Harness To Lower Crankcase

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11. Connect the engine wiring harness to the knock sensor.
12. Install the engine wiring harness to the wiring harness bracket (1).
    Fig 9: Installing Engine Wiring Harness To Wiring Harness Bracket

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    Important:  Installing the exhaust manifold/crossover pipe assembly with the engine on an engine stand is difficult. Remove the engine from the engine stand and install the exhaust manifold with the engine properly supported on the floor or on a bench.

    Important:  You MUST use a new exhaust manifold gasket when installing the exhaust manifold.

13. Position a new exhaust manifold gasket onto the right exhaust manifold.
14. Install the exhaust manifold bolts.
15. Place the right exhaust manifold, exhaust manifold gasket and bolts as an assembly in position on the right cylinder head.
16. Install the exhaust manifold bolts into the right cylinder head.

    Tighten 

    Tighten the right exhaust manifold bolts to 25 N.m (18 ft lbs).

    Fig 10: Installing Exhaust Manifold & Gasket

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17. Coat the oxygen sensor threads with anti-seize such as GM P/N 12377953 or equivalent.
18. Install the oxygen sensor (1).

    Tighten 

    Tighten the oxygen sensor to 41 N.m (30 ft lbs).

    Fig 11: Installing Oxygen Sensor

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    Important:  The EGR valve inlet pipe incorporates a crush seal connection at the water crossover. The EGR valve inlet pipe must be replaced if disconnected from the water crossover.

19. Install the NEW EGR valve inlet pipe (1).
20. Loosely install the EGR valve inlet pipe nut (3) to the exhaust crossover pipe.
21. Install the EGR valve inlet pipe bolt (2) to the water crossover.

    Tighten 

    Tighten the EGR valve inlet pipe bolt to 28 N.m (21 ft lbs).

22. Install the EGR valve inlet pipe nut (3) to the exhaust crossover pipe.

    Tighten 

    Tighten the EGR valve inlet pipe nut to 60 N.m (44 ft lbs).

    Fig 12: Installing EGR Valve Inlet Pipe

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23. Install a NEW A.I.R. manifold gasket.
24. Install the right A.I.R. manifold.
25. Install the right A.I.R. manifold bolts.

    Tighten 

    Tighten the right A.I.R. manifold bolts to 10 N.m (89 in lbs).

    Fig 13: Installing Right A.I.R. Manifold & Gasket

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26. Install the right A.I.R. control valve.
27. Install the right A.I.R. control valve bolts.

    Tighten 

    Tighten the right A.I.R. control valve bolts to 25 N.m (18 ft lbs).

    Fig 14: Installing Right A.I.R. Control Valve

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28. Install the right A.I.R. control valve pipe bolt and nut to the right A.I.R. manifold.

    Tighten 

    Tighten the right A.I.R. control valve pipe bolt and nut to 9 N.m (80 in lbs).

    Fig 15: Installing Right A.I.R. Control Valve Pipe

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29. Install the vacuum tube harness.
30. Connect the vacuum tubes (2) to the vacuum solenoid.
31. Connect the vacuum tube (1) to the right A.I.R. control valve.
    Fig 16: Connecting Vacuum Tubes To Vacuum Solenoid & Right A.I.R. Control Valve

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