Exhaust Manifold Installation - Right Side C/K/C3500HD

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. Install the exhaust manifold studs into the cylinder head (if necessary).

Tighten
Tighten the exhaust manifold studs to 20 N·m (15 lb ft).




2. Install the NEW right exhaust manifold gasket.
3. Install the right exhaust manifold.
4. Install the right exhaust manifold nuts and center bolt.

Tighten

•	Tighten the right exhaust manifold center bolt to 35 N·m (26 lb ft).

•	Tighten the right exhaust manifold nuts to 16 N·m (12 lb ft).




5. Install the right exhaust manifold heat shield.
6. Install the right exhaust manifold heat shield bolts and nuts.

Tighten
Tighten the right exhaust manifold heat shield bolts and nuts to 25 N·m (18 lb ft).




7. Install the right spark plugs.

Tighten
Tighten the right spark plugs to 20 N·m (15 lb ft).





Important: Fully install the spark plug wire by pushing on the exposed end of the spark plug boot. Do not push the spark plug wire onto the spark plug by using the metal heat shield.

8. Install the right spark plug wires to the spark plugs and ignition coils.



9. Install the exhaust gas recirculation (EGR) pipe and NEW EGR pipe gaskets.
10. Install the EGR pipe nuts to the right exhaust manifold.

Tighten
Tighten the EGR pipe nuts to 30 N·m (22 lb ft).

11. Install the EGR pipe bolts to the EGR adapter.

Tighten
Tighten the EGR pipe bolts to 30 N·m (22 lb ft).

12. Install the EGR pipe bracket bolt.

Tighten
Tighten the EGR pipe bracket bolt to 50 N·m (37 lb ft).




13. Install the secondary air injection pump pipe.
14. Install the secondary air injection pump pipe bolt to the right cylinder head.

Tighten
Tighten the secondary air injection pump pipe bolt to 50 N·m (37 lb ft).




15. Install the secondary air injection pipe and NEW secondary air injection pipe gasket.
16. Connect the secondary air injection pipe to the secondary air injection pump pipe.
17. Install the secondary air injection pipe bolts to the right exhaust manifold.

Tighten
Tighten the secondary air injection pipe bolts to 25 N·m (18 lb ft).

18. Install the secondary air injection pipe nut to the fuel injection fuel rail stud.

Tighten
Tighten the secondary air injection pipe nut to 12 N·m (106 lb in).