GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 Grand Prix 🢒 Preface 🢒 Cautions and Notices 🢒 Exhaust Manifold Replacement - Left Side

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.
  3. Remove the engine mount struts. Refer to Engine Mount Strut Replacement - Right Side and Engine Mount Strut Replacement - Left Side in Engine Mechanical - 3.8L.
  4. Remove the lower right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Right Lower in Engine Mechanical - 3.8L.

    5. Object Number: 153576 Size: MH
  5. Remove the exhaust crossover pipe bolts from the left exhaust manifold.
  6. Remove the left spark plugs from cylinders 1,3 and 5. Refer to Spark Plug Replacement in Engine Controls - 3.8L.
  7. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical - 3.8L.

    8. Object Number: 153577 Size: SH
  8. Remove the left engine lift bracket bolt and the nut.
  9. Remove the left engine lift bracket

    10. Object Number: 153578 Size: SH
  10. Remove the exhaust manifold heat shield nuts.
  11. Remove the exhaust manifold heat shield.

    12. Object Number: 97756 Size: SH
  12. Remove the exhaust manifold bolts and the nuts.
  13. Remove the exhaust manifold.
  14. Remove the exhaust manifold gasket.
  15. Clean and inspect the left exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection in Engine Mechanical - 3.8L.

Installation Procedure

    Object Number: 97756 Size: SH
  1. Install the new exhaust manifold gasket.
  2. Install the exhaust manifold.

    3. 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.

  3. Install the exhaust manifold bolts and the nuts.

    4. Tighten
    Tighten the bolts and the nuts to 30 N·m (22 lb ft).


    Object Number: 153578 Size: SH
  4. Install the exhaust manifold heat shield.
  5. Install the exhaust manifold heat shield nuts.

    6. Tighten
    Tighten the nuts to 20 N·m (15 lb ft).


    Object Number: 153577 Size: SH
  6. Install the engine lift bracket.
  7. Install the engine lift bracket bolt and the nut.

    8. Tighten
    Tighten the bolt and the nut to 30 N·m (22 lb ft).

  8. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical - 3.8L.
  9. Install the left spark plugs to cylinders 1, 3 and 5. Refer to Spark Plug Replacement in Engine Controls - 3.8L.

    10. Object Number: 153576 Size: MH
  10. Install the exhaust crossover bolts to the left exhaust manifold.

    11. Tighten
    Tighten the bolts to 20 N·m (15 lb ft).

  11. Install the lower right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Right Lower in Engine Mechanical - 3.8L.
  12. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Right Side and Engine Mount Strut Replacement - Left Side in Engine Mechanical - 3.8L.
  13. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.
  14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.