94. Exhaust Manifold Installation - Right With A.I.R.

Notice: Refer to Fastener Notice in Service Precautions.





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 the coolant heater bolt to 10 Nm (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 the exhaust manifold nuts (3) to 25 Nm (18 lb ft).





6. Coat the oxygen sensor threads with high temperature anti-seize, GM P/N 5613695 or equivalent.
7. Install the oxygen sensor (1).
Tighten the oxygen sensor to 40 Nm (30 lb ft).

Important: DO NOT reuse the old A.I.R. valve pipe gasket.





8. Install the NEW A.I.R. valve pipe gasket.
9. Install the A.I.R. valve.
10. Install the A.I.R. valve bolts through the mounting bracket.
Tighten the A.I.R. valve bolts to 9 Nm (80 lb in).
11. Install the A.I.R. valve pipe nuts to the exhaust manifold.
Tighten the A.I.R. valve pipe nuts to 9 Nm (80 lb in).





12. Connect the vacuum harness to the A.I.R. valve and vacuum solenoid valve.





13. Place the exhaust intermediate pipe (2) in position.

Notice: Refer to Fastener Notice in Service Precautions.

14. Install the intermediate pipe stud at the cylinder head (3) and the bolt at the lower crankcase (1).
14.1. Tighten the intermediate pipe-to-lower crankcase bolt (1) to 35 Nm (18 lb ft).
14.2. Tighten the intermediate pipe-to-cylinder head stud (3) to 25 Nm (18 lb ft).

Important: The 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.





15. Hand start the NEW EGR inlet tube to intermediate pipe nut (1) to prevent crossthreading.
Tighten the EGR inlet tube-to-intermediate pipe nut to 60 Nm (44 lb ft).
16. Connect the EGR inlet pipe flange (3) to the water crossover.
17. Install the EGR inlet pipe to water crossover flange bolt (2).
Tighten the EGR inlet tube to water crossover bolt to 25 Nm (18 lb ft).