GM Service Manual Online
For 1990-2009 cars only

Exhaust Manifold Installation - Right Side Without Secondary Air Injection (SAI)

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 683928  Size: SH

    Caution: When replacing the HO2S perform a code clear with a scan tool, regardless of whether or not a DTC is set. Performing a code clear will reset the HO2S resistance learned value. Failure to perform a code clear may result in an HO2S failure.

  1. Install the exhaust manifold studs and tighten to 10 N·m (89 lb in).

  2. Object Number: 1229781  Size: SH
  3. Install the exhaust manifold gasket.
  4. Install the exhaust manifold.
  5. Install the exhaust manifold bolts and nuts and tighten to 30 N·m (22 lb ft).
  6. Install the right side spark plugs and tighten to 15 N·m (11 lb ft).

  7. Object Number: 1403426  Size: SH
  8. Install the fuel injector sight shield cover bracket.
  9. Install the fuel injector sight shield cover bracket nuts and tighten to 30 N·m (22 lb ft).

  10. Object Number: 154526  Size: SH
  11. Install the right engine lift hook.
  12. Install the right engine lift hook nut and bolt and tighten to 30 N·m (22 lb ft).

Exhaust Manifold Installation - Right Side With Secondary Air Injection (SAI)

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 683928  Size: SH

    Caution: When replacing the HO2S perform a code clear with a scan tool, regardless of whether or not a DTC is set. Performing a code clear will reset the HO2S resistance learned value. Failure to perform a code clear may result in an HO2S failure.

  1. Install the exhaust manifold studs and tighten to 10 N·m (89 lb in).

  2. Object Number: 1229781  Size: SH
  3. Install the exhaust manifold gasket.
  4. Install the exhaust manifold.
  5. Install the exhaust manifold bolts and nuts and tighten to 30 N·m (22 lb ft).
  6. Install the right side spark plugs and tighten to 15 N·m (11 lb ft).

  7. Object Number: 1403426  Size: SH
  8. Install the fuel injector sight shield cover bracket.
  9. Install the fuel injector sight shield cover bracket nuts and tighten to 30 N·m (22 lb ft).

  10. Object Number: 154526  Size: SH
  11. Install the right engine lift hook.
  12. Install the right engine lift hook nut and bolt and tighten to 30 N·m (22 lb ft).

  13. Object Number: 1403432  Size: SH
  14. If necessary, install the secondary air pipe (644), gasket (647), and bolts (646) and assemble the injection pump (636) onto bracket (648) and tighten the secondary air injection pump pipe bolts to 10 N·m (89 lb in).
  15. Install gasket (645), secondary air injection pump assembly and nuts (641) onto the engine and tighten to 10 N·m (89 lb in).
  16. Install the secondary air injection pump assembly mounting bolts (637, 649) and tighten to 10 N·m (89 lb in).

  17. Object Number: 1403429  Size: SH
  18. Loosen the hose clamp and install the secondary air injection pipe (640) onto the valve and reinstall the hose clamp.