Installation Procedure

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, 2003 Chevrolet RV Cutaway, and 2003 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

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.

Sub-assemble the NEW gaskets, the spark plug wire shields, and the bolts to the exhaust manifold.
Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners 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.
Install the exhaust manifold.
Tighten
1. Tighten the exhaust manifold bolts - First Pass to 15 N.m (11 ft lbs).
2. Tighten the exhaust manifold bolts - Second Pass to 30 N.m (22 ft lbs).
  
  Fig 1: Identifying Tabs On Exhaust Manifold Gaskets
  Courtesy of GENERAL MOTORS CORP.
Install the spark plugs.
Install the spark plug wires to the spark plugs.
Install the spark plug wire support and bolts.
Tighten

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

Fig 2: Installing Spark Plugs, Spark Plug Wires, Support & Support Bolts
Courtesy of GENERAL MOTORS CORP.
Install the EGR valve inlet pipe to the exhaust manifold.
Tighten

Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N.m (22 ft lbs).

Fig 3: Installing EGR Valve Inlet Pipe
Courtesy of GENERAL MOTORS CORP.
Install the catalytic converter assembly. Refer to Catalytic Converter Replacement (4.3L) or Catalytic Converter Replacement (Dual Exhaust - Right) or Catalytic Converter Replacement (Dual Exhaust - Left) .
Install the fender wheelhouse extension (1).
Install the left front tire.
Lower the vehicle.

Fig 4: Installing Fender Wheelhouse Extension
Courtesy of GENERAL MOTORS CORP.
Connect the ECT gage sensor electrical connector.
Install the engine cover.

Fig 5: Connecting ECT Gage Sensor Electrical Connector
Courtesy of GENERAL MOTORS CORP.