Exhaust Manifold Installation Right

Notice: 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.

1. If the engine is equipped with coolant heaters, install the right side (1) heater as follows:

1.1.	Place the coolant heater (1) in position on the cylinder block.

1.2.	Install the coolant heater bolt.

Tighten
Tighten the coolant heater bolt to 10 N·m (89 lb in).




2. Position a new manifold gasket (1) in place on the cylinder head studs.
3. Using two hands, position the manifold (2) onto the cylinder head.
4. Install two outer manifold nuts (3) to hold the manifold in place.
5. Install the remaining manifold nuts.

Tighten
Tighten the exhaust manifold nuts (3) to 25 N·m (18 lb ft).




6. Coat the oxygen sensor threads with high temperature anti-seize, GM P/N 5613695 or equivalent.
7. Install the oxygen sensor (1).

Tighten
Tighten the oxygen sensor to 40 N·m (30 lb ft).

Exhaust Manifold Installation Left

1. Place the exhaust intermediate pipe (2) in position.

Notice: 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.

2. Install the intermediate pipe retaining stud at the cylinder head (3) and the bolt at the lower crankcase (1).

Tighten

1. Tighten the intermediate pipe-to-lower crankcase retaining bolt (1) to 35 N·m (18 lb ft).
2. Tighten the intermediate pipe-to-cylinder head retaining stud (3) to 25 N·m (18 lb ft).



3. Hand start the EGR feed tube to intermediate pipe nut (1) to prevent crossthreading.

Tighten
Tighten the EGR feed tube-to-intermediate pipe nut to 60 N·m (44 lb ft).

4. Connect the EGR feed pipe flange (3) to the water crossover.
5. Install the EGR feed pipe to water crossover flange retaining bolt (3).

Tighten
Tighten the EGR feed tube to water crossover bolt to 25 N·m (18 lb ft).




6. Insert the end of the oil level indicator tube in the cylinder block. Align the mounting tab with the mounting bolt hole.
7. Install the oil level tube retaining bolt.

Tighten
Tighten the oil level tube retaining bolt to 10 N·m (89 lb ft).

8. Install the oil level indicator.



9. If the engine is equipped with coolant heaters, install the left side (1) heater as follows:

9.1.	Place the coolant heater (1) in position on the cylinder block.

9.2.	Install the coolant heater retaining bolt.

Tighten
Tighten the coolant heater retaining bolt to 10 N·m (89 lb in).




10. With the manifold still on the bench, position a new manifold gasket (1) in place on the manifold sealing surface.
11. Install two outer manifold bolts (6) in the manifold to retain the gasket.
12. Install a new manifold to intermediate pipe flange gasket (5).
13. Using two hands, place the manifold (2) in the intermediate pipe and onto the cylinder head.
14. Install new manifold flange bolts (3) for maximum joint integrity. Hand tighten. Do not torque the flange bolts to specification until the engine is mounted in the vehicle.
15. Hand tighten the two outer manifold bolts.
16. Install the remaining manifold retaining bolts.

Tighten
Tighten the exhaust manifold retaining bolts (6) to 25 N·m (18 lb ft).




17. Coat the oxygen sensor threads with high temperature anti-seize, GM P/N 5613695 or equivalent.
18. Install the oxygen sensor (1).

Tighten
Tighten the oxygen sensor to 40 N·m (30 lb ft).