Installation Procedure

WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance.
The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material.
Do not apply sealant to the first 3 threads of the bolt.

Fig 1: View Of Exhaust Manifold Heat Shield & Bolts

GM1708619

Courtesy of GENERAL MOTORS CORP.

CAUTION: Refer to Fastener Caution .

If the exhaust manifold was replaced, position and install the exhaust manifold heat shield, and bolts to the exhaust manifold.
Tighten: Tighten the bolts to 9 N.m (80 lb in).

Fig 2: View Of Exhaust Manifold, Gasket & Bolts

GM1708618

Courtesy of GENERAL MOTORS CORP.

Clean the threads of the exhaust manifold bolts.
Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts.
Install a NEW catalytic converter seal to the exhaust manifold.
Position the NEW exhaust manifold gasket and exhaust manifold to the cylinder head.
Ensure that the catalytic converter seal is seated to the catalytic converter.
Install the exhaust manifold bolts.
Tighten:
1. Tighten the bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
2. Tighten the bolts a final pass to 20 N.m (15 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
Using a flat punch, bend the gasket tab at the rear of the gasket around the cylinder head edge.

Fig 3: View Of Oil Level Indicator, Tube Bolt, Indicator Tube & O-Ring Seal

GM1658141

Courtesy of GENERAL MOTORS CORP.

NOTE: The O-ring seal may be reused if not cut or damaged.

Inspect the O-ring seal (421) for cuts or damage, replace as necessary.
Lubricate the O-ring seal (421) with clean engine oil.
Install the oil level indicator tube (420) to the engine block.
Install the oil level indicator tube bolt (419).
Tighten: Tighten the bolt 25 N.m (18 lb ft).

Fig 4: Locating Spark Plug Wires

GM1962351

Courtesy of GENERAL MOTORS CORP.

Install the spark plug wires (1) to the spark plugs.
Install the spark plug wires to the ignition coils.
Inspect the spark plug wires for proper installation.
1. Push sideways on each boot in order to inspect the seating.
2. Reinstall any loose boot.
Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) or Front Wheelhouse Liner Replacement - Right Side (GMC) .
Fully raise and support the vehicle.

Fig 5: View Of Exhaust Manifold, Gasket & Catalytic Converter

GM1708617

Courtesy of GENERAL MOTORS CORP.

Install the catalytic converter to exhaust manifold nuts, 1500 series shown, 2500 series similar.
Tighten: Tighten the nuts to 50 N.m (37 lb ft).

Partially lower the vehicle in order to work through the wheel opening.

Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis) or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) .