Exhaust Manifold Replacement - Right Side

Exhaust Manifold Replacement - Right Side

Special Tools

J 42640 Steering Column Lock Pin

Removal Procedure
Warning: Refer Exhaust Service Warning Service Precautions .
Warning: Refer to Protective Goggles and Glove Warning. Protective Goggles and Glove Warning




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.

Caution: 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 (Exhaust Manifold Rear Pipe Replacement).
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 (1) from the lower control arms.





Warning

Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear or to the intermediate shaft. This damage may cause loss of steering control, which could result in an accident and possible 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. Support the rear of the frame with a tall screw type jack.




17. Remove the 4 rearward engine frame-to-body bolts (1).
18. Lower the screw type jack approximately 4 cm (1.5 in) allowing the rear of the engine frame to lower.




19. Remove the HO2S.




20. Remove the exhaust manifold nuts.
21. Remove the exhaust manifold (2).
22. 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 the exhaust manifold (2).

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the exhaust manifold nuts.

Tighten the nuts to 25 Nm (18 lb ft).




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

Tighten the sensor to 41 Nm (30 lb ft).




6. Raise the engine frame into position.
7. Install the 4 rearward engine frame-to-body bolts (1).

Tighten the bolts to 191 Nm (141 lb ft).




8. Remove the screw type jack.





Warning

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

9. Connect the intermediate shaft to the steering gear.
10. Install the intermediate shaft pinch bolt.

Tighten the bolt to 45 Nm (33 lb ft).

11. Install the intermediate shaft seal.




12. Connect the electronic suspension position sensor link ball studs (1) to the lower control arms.




13. Install the steering gear heat shield.
14. Install the steering gear heat shield bolts.

Tighten the bolts to 9 Nm (80 lb in).




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




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




20. Remove the J 42640 from the steering column.




21. Connect the engine harness electrical connector (2) to the HO2S.
22. Install the HO2S clip (5) to the AIR valve hose bracket.
23. Install the CPA retainer (3).