Exhaust Manifold Replacement - Right Side
Exhaust Manifold Replacement - Right Side
Special Tools
J 42640 Steering Column Lock Pin
Removal Procedure
Warning: Refer to Exhaust Service Warning (Exhaust Service Warning).
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: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components:
* The steering column
* The intermediate shaft(s)
* The steering gear
After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil.
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-seize 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).