Rear Exhaust Manifold Replacement: Installation

Install exhaust manifold and new gasket.
Install exhaust manifold nuts.
Torque:

Exhaust Manifold Nut: 20 N.m (15 ft-lbs)

Fig 1: Installing Exhaust Manifold & Gasket
Courtesy of GENERAL MOTORS CORP.
Install rear exhaust manifold pipe assembly and gaskets.
NOTE: Do not tighten fasteners.
Install exhaust manifold to rear exhaust manifold pipe nuts.

Fig 2: Bolting Exhaust Pipe To Rear Exhaust Manifold
Courtesy of GENERAL MOTORS CORP.
Install front exhaust manifold pipe to rear exhaust manifold pipe attachment bolts.
Torque:

Exhaust Manifold Pipe Bolts: 20 N.m (15 ft-lbs)

Fig 3: Attaching Front & Rear Exhaust Pipes
Courtesy of GENERAL MOTORS CORP.
Install rear exhaust manifold pipe to resonator bolts.
Torque:

Exhaust Manifold Pipe Bolts: 20 N.m (15 ft-lbs)

Fig 4: Connecting Resonator To Rear Exhaust Pipe
Courtesy of GENERAL MOTORS CORP.
Tighten rear exhaust manifold pipe to exhaust manifold nuts.
Torque:

Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 30 N.m (25 ft-lbs)
Lower vehicle.
Install EGR pipe to exhaust manifold and EGR flange.
Torque:

EGR Pipe Bolts: 25 N.m (19 ft-lbs)

NOTE: Always use a nickle-based anti-seize compound Saturn P/N 21485279 (or equivalent) on the threads of the heated oxygen sensor. If the heated oxygen sensor is replaced, do not apply anti-seize to the new sensor. New sensors have anti-seize pre-applied. Never use silicon product; silicon products will cause damage to oxygen sensor.
Install heated oxygen sensor using O2 sensor wrench J39194C.
Torque:

Oxygen Sensors (Exhaust Manifold): 50 N.m (37 ft-lbs)

Fig 5: Installing HO2S Sensor
Courtesy of GENERAL MOTORS CORP.
Connect rear exhaust manifold pipe heated oxygen sensor electrical connections.
Install exhaust manifold pipe heat shield.
Torque:

Exhaust Manifold Pipe Heat Shield Bolts: 8 N.m (71 in-lbs)

Fig 6: Installing Exhaust Pipe Heat Shields
Courtesy of GENERAL MOTORS CORP.
Start vehicle and inspect for exhaust leaks.