Exhaust Manifold Installation - Right Side W/O RPO NC1 or NF7

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 12377953 or equivalent.
7. Install the oxygen sensor (1).

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




8. Place the exhaust intermediate pipe (2) in position.
9. Install the intermediate pipe stud at the cylinder head (3) and the bolt at the lower crankcase (1).

Tighten

1. Tighten the intermediate pipe-to-lower crankcase bolt (1) to 30 N·m (22 lb ft).
2. Tighten the intermediate pipe-to-cylinder head stud (3) to 30 N·m (22 lb ft).




Important: The exhaust gas recirculation (EGR) valve inlet pipe incorporates a crush seal connection at the water crossover. The EGR valve inlet pipe must be replaced if disconnected from the water crossover.

10. Hand start the NEW EGR inlet tube to intermediate pipe nut (1) to prevent crossthreading.

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

11. Connect the EGR inlet pipe flange (3) to the water crossover.
12. Install the EGR inlet pipe to water crossover flange bolt (2).

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

Exhaust Manifold Installation - Right Side With RPO NC1 or NF7

Notice: Refer to Fastener Notice in the Preface section.




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 12377953 or equivalent.
7. Install the oxygen sensor (1).

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





Important: DO NOT reuse the old secondary air injection (AIR) valve pipe gasket.

8. Install the NEW AIR valve pipe gasket.
9. Install the AIR valve.
10. Install the AIR valve bolts through the mounting bracket.

Tighten
Tighten the AIR valve bolts to 9 N·m (80 lb in).

11. Install the AIR valve pipe nuts to the exhaust manifold.

Tighten
Tighten the AIR valve pipe nuts to 9 N·m (80 lb in).




12. Place the exhaust intermediate pipe (2) in position.
13. Install the intermediate pipe stud at the cylinder head (3) and the bolt at the lower crankcase (1).

Tighten

1. Tighten the intermediate pipe-to-lower crankcase bolt (1) to 30 N·m (22 lb ft).
2. Tighten the intermediate pipe-to-cylinder head stud (3) to 30 N·m (22 lb ft).




Important: The exhaust gas recirculation (EGR) valve inlet pipe incorporates a crush seal connection at the water crossover. The EGR valve inlet pipe must be replaced if disconnected from the water crossover.

14. Hand start the NEW EGR inlet tube to intermediate pipe nut (1) to prevent crossthreading.

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

15. Connect the EGR inlet pipe flange (3) to the water crossover.
16. Install the EGR inlet pipe to water crossover flange bolt (2).

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