Exhaust Manifold Replacement - Right Side (RPO LD8)

Exhaust Manifold Replacement - Right Side (RPO LD8)

Tools Required

J 42640 Steering Column Anti-Rotation Pin

Removal Procedure
Caution: Refer to Exhaust Service Caution.
Caution: Refer to Protective Goggles and Gloves Caution.




1. Remove the connector position assurance (CPA) retainer (3).
2. Disconnect the engine harness electrical connector (2) from the heated oxygen sensor (HO2S).
3. Remove the HO2S clip (5) from the secondary air injection (AIR) valve hose bracket.





Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.

4. Lock the steering column by installing the J 42640 into the underside of the steering column.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
6. Remove the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement (RPO LD8) (Exhaust Manifold Rear Pipe Replacement (RPO LD8)).
7. Remove the AIR check valve. Refer to Secondary Air Injection Check Valve Replacement (Service and Repair).




8. Disconnect the engine harness clip (2) from the steering gear heat shield.




9. Disconnect the engine harness clip (3) from the steering gear heat shield.




10. Remove the steering gear heat shield bolts.
11. Remove the steering gear heat shield.




12. Disconnect the electronic suspension position sensor link ball studs from the lower control arms.





Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

13. Unsnap and remove the intermediate shaft seal.
14. Remove the intermediate shaft pinch bolt.
15. Separate the intermediate shaft from the steering gear.




16. Remove the right engine mount to frame nut.




17. Remove the left engine mount to frame nut.




18. Remove the transaxle mount to frame nuts.




19. Support the rear of the frame with a tall screw type jack.




20. Remove the 4 rearward engine frame-to-body bolts (1) (left side shown, right side similar).
21. Lower the screw type jack approximately 4 cm (1.5 in) allowing the rear of the engine frame to lower.




22. Remove the HO2S.




23. Remove the exhaust manifold nuts.
24. Remove the exhaust manifold (2).
25. Remove and discard the exhaust manifold gasket (1).

Installation Procedure




1. Install a NEW exhaust manifold gasket (1) onto the cylinder head studs.
2. Install exhaust manifold (2).

Notice: Refer to Fastener Notice (Fastener Notice).

3. Install the exhaust manifold nuts.

Tighten the nuts to 25 N.m (18 lb ft).




4. If reusing the old HO2S, coat the threads with anti-seize compound, GM P/N 12377953 or equivalent.
5. Install the HO2S.

Tighten the sensor to 41 N.m (30 lb ft).




6. Raise the engine frame into position.
7. Install the 4 rearward engine frame-to-body bolts (1) (left side shown, right side similar).

Tighten the bolts to 191 N.m (141 lb ft).




8. Remove the screw type jack.




9. Install the transaxle mount to frame nuts.

Tighten the nuts to 50 N.m (37 lb ft).




10. Install the left engine mount to frame nut.

Tighten the nuts to 80 N.m (59 lb ft).




11. Install the right engine mount to frame nut.

Tighten the nuts to 80 N.m (59 lb ft).





Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

12. Connect the intermediate shaft to the steering gear.
13. Install the intermediate shaft pinch bolt.

Tighten the bolt to 45 N.m (33 lb ft).

14. Install the intermediate shaft seal.




15. Connect the electronic suspension position sensor link ball studs to the lower control arms.




16. Install the steering gear heat shield.
17. Install the steering gear heat shield bolts.

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




18. Connect the engine harness clip (3) to the steering gear heat shield.




19. Connect the engine harness clip (2) to the steering gear heat shield.
20. Install the AIR check valve. Refer to Secondary Air Injection Check Valve Replacement (Service and Repair).
21. Install the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement (RPO LD8) (Exhaust Manifold Rear Pipe Replacement (RPO LD8)).
22. Lower the vehicle.




23. Remove the J 42640.




24. Connect the engine harness electrical connector (2) to the HO2S.
25. Install the HO2S clip (5) to the AIR valve hose bracket.
26. Install the CPA retainer (3).