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Exhaust Manifold Installation-Right (G)

WARNING: This page is about a different car, the 2002 GMC Yukon XL, 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 in Cautions and Notices.
  1. Install the exhaust manifold studs into the cylinder head, if necessary.

    Tighten 

    Tighten the exhaust manifold studs to 20 N.m (15 lb ft).

    Fig 1: Right Exhaust Manifold Studs (G)
    G01675670Courtesy of GENERAL MOTORS CORP.
  2. Install the NEW right exhaust manifold gasket.
  3. Install the right exhaust manifold.
  4. Install the right exhaust manifold nuts and center bolt.

    Tighten 

    • Tighten the right exhaust manifold center bolt to 35 N.m (26 lb ft).
    • Tighten the right exhaust manifold nuts to 16N.m (12lbft).
    Fig 2: Right Exhaust manifold, Gasket, Bolts & Nuts (G)
    G01675671Courtesy of GENERAL MOTORS CORP.
  5. Install the right exhaust manifold heat shield.
  6. Install the right exhaust manifold heat shield bolts and nuts.

    Tighten 

    Tighten the right exhaust manifold heat shield bolts and nuts to 25 N.m (19 lb ft).

    Fig 3: Right Exhaust Manifold Heat Shield, Bolts & Nuts (G)
    G01675672Courtesy of GENERAL MOTORS CORP.
  7. Install the right spark plugs.

    Tighten 

    Tighten the right spark plugs to 20 N.m (15 lb ft).

    Fig 4: Right Spark Plug
    G01675673Courtesy of GENERAL MOTORS CORP.

    Important:  Fully install the spark plug wire by pushing on the exposed end of the spark plug boot. Do not push the spark plug wire on to the spark plug by using the metal heat shield.

  8. Install the right spark plug wires to the spark plugs and ignition coils.
    Fig 5: Right Spark Plug Wire
    G01675674Courtesy of GENERAL MOTORS CORP.
  9. Install the exhaust gas recirculation (EGR) pipe and NEW EGR pipe gaskets.
  10. Install the EGR pipe nuts to the right exhaust manifold.

    Tighten 

    Tighten the EGR pipe nuts to 25 N.m (19 lb ft).

  11. Install the EGR pipe bolts to the EGR valve.

    Tighten 

    Tighten the EGR pipe bolts to 25 N.m (19 lb ft).

  12. Install the EGR pipe bracket bolt.

    Tighten 

    Tighten the EGR pipe bracket bolt to 50 N.m (37 lb ft).

    Fig 6: Right EGR Pipe, Bracket & Bolt (G)
    G01675675Courtesy of GENERAL MOTORS CORP.
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