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Installation Procedure

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: Exhaust Manifold Heat Shield And Bolts
    GM1708619Courtesy of GENERAL MOTORS CORP.
    CAUTION:

    Refer to Fastener Caution .

  1. 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).

    2. Fig 2: Exhaust Manifold, Gasket And Bolts
    GM1708618Courtesy of GENERAL MOTORS CORP.
  2. Clean the threads of the exhaust manifold bolts.
  3. 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.
  4. Install a NEW catalytic converter seal to the exhaust manifold.
  5. Position the NEW exhaust manifold gasket and exhaust manifold to the cylinder head.
  6. Ensure that the catalytic converter seal is seated to the catalytic converter.
  7. 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.
  8. Using a flat punch, bend the gasket tab at the rear of the gasket around the cylinder head edge.
  9. Install the oil level indicator tube to the engine block. Refer to Oil Level Indicator Tube Replacement .
    10. Fig 3: Spark Plug Wires
    GM1962351Courtesy of GENERAL MOTORS CORP.
  10. Install the spark plug wires (1) to the spark plugs.
  11. Install the spark plug wires to the ignition coils.
  12. 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.
  13. Fully raise and support the vehicle.
    14. Fig 4: Exhaust Manifold, Gasket And Catalytic Converter
    GM1708617Courtesy of GENERAL MOTORS CORP.
  14. 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).

  15. Partially lower the vehicle in order to work through the wheel opening.
  16. Install the front wheel house liner - right front. Refer to Front Wheelhouse Liner Replacement - Right Side .
  17. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) , Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) .
  18. Inspect the exhaust system for leaks.
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