Exhaust Manifold Replacement - Right (M AP) (E GR) (EVAP)€¦ · Remove the Exhaust Gas Recirculation (E GR) valve. 7. Remove the ignition module and the ignition coils with the

Exhaust Manifold Replacement - Right

Removal Procedure 1. Remove the windshield wiper motor cover. 2. Remove the throttle body air inlet duct. 3. Remove the accelerator cable bracket from the throttle body. 4. Rotate the engine for service access. 5. Remove the Manifold Air Pressure (MAP) sensor. 6. Remove the Exhaust Gas Recirculation (EGR) valve. 7. Remove the ignition module and the ignition coils with the bracket. 8. Remove the spark plug wires from the engine right bank spark plugs. 9. Disconnect the oxygen sensor electrical connector. 10. Remove the Evaporative Emissions (EVAP) solenoid bracket. 11. Remove the exhaust crossover pipe nuts/studs from the engine right bank exhaust manifold. 12. Raise and support the vehicle. Refer to Vehicle Lifting. 13. Remove the catalytic converter.

14. Remove the exhaust manifold heat shield bolts. 15. Remove the exhaust manifold heat shields.

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16. Remove the exhaust manifold nuts. 17. Remove the exhaust manifold. 18. Remove the exhaust manifold gasket. 19. Lower the vehicle. 20. Clean the engine right side exhaust manifold sealing surfaces and the cylinder head sealing surfaces. 21. If you are REPLACING the engine right side exhaust manifold, remove the Exhaust Gas Recirculation (EGR) valve pipe. 22. If you are REPLACING the engine right side exhaust manifold, remove the Heated Oxygen Sensor (HO2S).

Installation Procedure 1. If removed, install the Heated Oxygen Sensor (HO2S). 2. If removed, install the Exhaust Gas Recirculation (EGR) valve pipe. 3. Raise and support the vehicle. Refer to Vehicle Lifting.


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4. Install the exhaust manifold gasket. 5. Install the exhaust manifold.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the exhaust manifold nuts. Tighten the exhaust manifold nuts to 16 Nm (12 ft. lbs.).


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7. Install the exhaust manifold lower heat shield. 8. Install the exhaust manifold upper heat shield. 9. Install the exhaust manifold heat shield bolts. Tighten the exhaust manifold heat shield bolts to 10 Nm (89 inch lbs.). 10. Install the catalytic converter. 11. Lower the vehicle. 12. Install the exhaust crossover pipe nuts/studs to the engine right side exhaust manifold. 13. Install the exhaust crossover pipe heat shield. 14. Lower the vehicle. 15. Connect the Heated Oxygen Sensor (HO2S) electrical connector. 16. Install the EVAP solenoid bracket. 17. Install the spark plug wires to the engine right bank spark plugs. 18. Install the ignition module and the ignition coils with the bracket. 19. Install the Exhaust Gas Recirculation (EGR) valve to the intake manifold. 20. Install the Manifold Absolute Pressure (MAP) sensor. 21. Rotate the engine back to the original position. 22. Install the accelerator cable bracket to the throttle body. 23. Install the throttle body air inlet duct. 24. Install the windshield wiper motor cover.

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Exhaust Manifold Replacement - Left

Removal Procedure 1. Remove the throttle body air inlet duct. 2. Drain the engine coolant from the cooling system. 3. Remove the right engine mount strut bracket. 4. Disconnect the inlet radiator hose from the engine. 5. Remove the thermostat bypass pipe. 6. Remove the exhaust crossover pipe bolts from the engine left side exhaust manifold.

7. Remove the exhaust manifold heat shield bolts. 8. Remove the exhaust manifold heat shield. 9. Remove the exhaust manifold nuts. 10. Remove the exhaust manifold.


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11. Remove the exhaust manifold gasket. 12. Clean the engine left side exhaust manifold to the engine left side cylinder head sealing surfaces.

Installation Procedure

1. Install the exhaust manifold gasket. 2. Install the exhaust manifold.



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3. Install the exhaust manifold nuts. Tighten the exhaust manifold nuts to 16 Nm (12 ft. lbs.).

4. Install the exhaust manifold heat shield. 5. Install the exhaust manifold heat shield bolts. Tighten the exhaust manifold heat shield bolts to 10 Nm (89 inch lbs.). 6. Install the exhaust crossover pipe. 7. Install the thermostat bypass pipe. 8. Connect the inlet radiator hose to the engine. 9. Install the right engine mount strut bracket. 10. Fill the cooling system with engine coolant. 11. Install the throttle body air inlet duct.



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Exhaust Crossover Pipe Replacement

Removal Procedure 1. Remove the throttle body air inlet duct. 2. Drain the engine coolant from the cooling system. 3. Remove the inlet radiator hose from the engine. 4. Remove the thermostat bypass pipe.

5. Remove the exhaust crossover pipe heat shield bolts. 6. Remove the exhaust crossover pipe heat shield.

Exhaust Crossover Pipe |Service and Repair, Removal and Replacement http://repair.alldata.com/alldata/article/display.action?componentId=647...

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7. Remove the exhaust crossover pipe nuts. 8. Remove the exhaust crossover pipe.


1. Install the exhaust crossover pipe.


2. Install the exhaust crossover pipe nuts. Tighten the exhaust crossover pipe nuts to 25 Nm (18 ft. lbs.).


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3. Install the exhaust crossover pipe heat shield. 4. Install the exhaust crossover pipe heat shield bolts. Tighten the exhaust crossover pipe heat shield bolts to 10 Nm (89 inch lbs.). 5. Install the thermostat bypass pipe. 6. Install the inlet radiator hose to the engine. 7. Fill the cooling system with engine coolant. 8. Install the throttle body air inlet duct.



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Intake Manifold Replacement - Upper

Removal Procedure

Important: The fuel injector wiring harness connectors must be connected to their respective fuel injectors. Failure to connect the fuelinjector connectors to their respective fuel injectors may result in excessive exhaust emissions and poor engine performance.

1. Drain the engine coolant from the cooling system. 2. Remove the throttle body air inlet duct.

3. Remove the accelerator control and cruise control cables with bracket from the throttle body. 4. Disconnect the wiring harness connectors from the following throttle body components: ^ Throttle Position (TP) sensor ^ Idle Air Control (IAC) valve 5. Disconnect the engine left side spark plug wires. 6. Disconnect the engine left side spark plug wire harness attachment clip. Disconnect the throttle body heater hoses. 8. Disconnect the vacuum hoses from the Evaporative Emission (EVAP) canister purge solenoid valve. 9. Remove the EVAP canister purge solenoid valve.

Intake Manifold |Service and Repair, Removal and Replacement: Upper I... http://repair.alldata.com/alldata/article/display.action?componentId=123...

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10. Remove the ignition coil bracket.

11. Disconnect the wiring harness from the Manifold Air Pressure (MAP) sensor.


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12. Disconnect the vacuum harness from the MAP sensor and the upper intake manifold.

13. Disconnect and remove the emission control vacuum harness. 14. Disconnect the vacuum brake booster hose from the upper intake manifold. 15. Disconnect the vacuum hose connections from the upper intake manifold. ^ Heating, Ventilation and Air Conditioning (HVAC) vacuum source hose ^ Fuel pressure regulator 16. Remove the Exhaust Gas Recirculation (EGR) valve. 17. Remove the MAP sensor and the bracket.


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18. Remove the upper intake manifold studs and bolts.

19. Remove the upper intake manifold.


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20. If you are REPLACING the intake manifold, remove the throttle body.

21. Remove the upper intake manifold gasket. 22. Clean and inspect the upper intake manifold.



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1. If removed, install the throttle body.

2. Install the upper intake manifold gasket.


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3. Install the upper intake manifold.

4. Install the MAP sensor and the bracket.


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5. Install the upper intake manifold studs and bolts. 6. Install the Exhaust Gas Recirculation (EGR) valve. 7. Connect the vacuum hose connections to the upper intake manifold. ^ Heater and air conditioning vacuum source hose ^ Fuel pressure regulator 8. Connect the vacuum brake booster hose to the upper intake manifold.

9. Install and connect the emission control vacuum harness.


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10. Connect the vacuum hose to the MAP sensor and the upper intake manifold.

11. Connect the wiring harness to the MAP sensor.


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12. Install the ignition coil bracket with the coils. 13. Install the EVAP canister purge solenoid valve.

14. Connect the vacuum hoses to the EVAP canister purge solenoid valve. 15. Connect the throttle body heater hoses. 16. Connect the engine left side spark plug wire harness attachment clip. 17. Connect the engine left side spark plug wires. 18. Connect the wiring harness connectors to the throttle body.


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19. Install the accelerator control and cruise control cables with bracket to the throttle body. 20. Install the throttle body air inlet duct. 21. Fill the cooling system with engine coolant.



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Intake Manifold Replacement - Lower

^ Tools Required - J 36660-A Torque Angle Meter

Removal Procedure


1. Remove the upper intake manifold. 2. Remove the engine left side valve rocker arm cover. 3. Remove the engine right side valve rocker arm cover. 4. Disconnect the wiring harness from the Engine Coolant Temperature (ECT) sensor.

Important: Use masking tape or another appropriate method in order to identify each fuel injector wiring harness connector cylindernumber.

Intake Manifold |Service and Repair, Removal and Replacement: Intake... http://repair.alldata.com/alldata/article/display.action?componentId=123...

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5. Disconnect and remove the fuel injector, Manifold Air Pressure (MAP) and ECT wiring harness. 6. Remove the fuel feed and return pipe from the fuel injector rail.

7. Remove the fuel injector rail.

Important: Do NOT disconnect the power steering pipes or hoses from the power steering pump.

8. Remove the power steering pump from the front engine cover and reposition aside. 9. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and reposition aside. 10. Disconnect the inlet radiator hose from the engine.


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11. Disconnect the thermostat bypass hose from the lower intake manifold pipe.

12. Remove the lower intake manifold bolts.


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13. Remove the lower intake manifold. 14. Loosen the valve rocker arms and remove the push rods.

15. Remove the lower intake manifold gaskets and seals. 16. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block. 17. Clean and inspect the lower intake manifold. 18. If you are replacing the lower intake manifold, remove the ECT sensor.


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19. If you are REPLACING the lower intake manifold, remove the thermostat.


1. Apply 8 - 12 mm (0.08 - 0.11 inch) bead of RTV Sealer GM P/N 12345739 or equivalent on each ridge where front and rear of thelower intake manifold contact the engine block (1). 2. Install the lower intake manifold gaskets. 3. Install the push rods and tighten the valve rocker arms.


4. Install the valve rocker arm bolts. Use the J 36660-A to tighten the bolts to 19 Nm (14 ft. lbs.) plus 30 degrees.


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5. Install the lower intake manifold. 6. Install the lower intake manifold bolts.

7. Tighten the lower intake manifold bolts.

Notice: Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.

8. Apply sealer GM P/N 12345382 or the equivalent to the lower intake manifold bolt threads.


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9. Install NEW lower intake manifold bolts.

The torque specification is a 2-step process; tighten the vertical lower intake manifold bolts (the four middle ones) to 7 Nm (62 lb in).Tighten the diagonal lower intake manifold bolts (two on each end) to 7 Nm (62 lb in).Tighten the vertical lower intake manifold bolts (thefour middle ones) to 13 Nm (115 lb in). Tighten the diagonal lower intake manifold bolts (two on each end) to 25 Nm (18 lb ft).

10. Connect the thermostat bypass hose to the lower intake manifold pipe. 11. Connect the inlet radiator hose from the engine.


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12. Connect the heater inlet pipe and heater hose to the lower intake manifold. 13. Install the power steering pump to the front engine cover.

14. Install the fuel injector rail. 15. Connect the fuel feed and return pipe to the fuel injector rail.



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16. Install and connect the fuel injector, MAP and ECT wiring harness. 17. Install the wiring harness to the ECT sensor. 18. Install the engine right side valve rocker arm cover. 19. Install the engine left side valve rocker arm cover.

20. Install the upper intake manifold.



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This article has been updated with TSB 02-06-01-003B, 4/15/08 This bulletin is being revised to include a Notice advising that the cylinder head bolts are NOT TO BE RE-USED. Please discardCorporate Bulletin Number 02-06-01-003A.

Cylinder Head Replacement - Right

^ Tools Required - J 36660-A Torque Angle Meter

Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the engine coolant from the cooling system. 3. Drain the engine oil. 4. Lower the vehicle.

5. Remove the lower intake manifold. 6. Remove the exhaust crossover pipe. 7. Remove the engine right side spark plug wires from the spark plugs. 8. Remove the engine right side exhaust manifold. 9. Remove the pushrods and valve rocker arms. 10. Remove the cylinder head bolts. 11. Remove the cylinder head. 12. Remove the cylinder head gasket. 13. Remove the engine right side spark plugs from the cylinder head.

Cylinder Head Assembly |Service and Repair, Procedures: Cylinder Hea... http://repair.alldata.com/alldata/article/display.action?componentId=65&...

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14. Clean the following areas: - The gasket sealing surfaces on the cylinder head, cylinder block, and intake manifolds - The cylinder block bolt threads - The cylinder head bolts 15. Clean and inspect the cylinder head.


1. Install the cylinder head gasket.


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2. Install the cylinder head.


Notice: This component uses torque-to-yield bolts. When servicing this component, do not re-use the bolts. New torque-to-yield boltsmust be installed. Re-using used torque-to-yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW torque-to-yield bolts may lead to engine damage.

3. Install the NEW cylinder head bolts. - Tighten the NEW cylinder head bolts to 60 Nm (44 lb ft) in the order shown. Use the J 36660-A torque angle meter in order to rotatethe cylinder head bolts an additional 95 degrees.

4. Install the engine right side spark plugs. 5. Install the engine right side exhaust manifold. 6. Install the engine right side spark plug wires to the spark plugs. 7. Install the exhaust crossover pipe. 8. Install the pushrods and valve rocker arms. 9. Install the lower intake manifold. 10. Install the upper intake manifold. 11. Fill the engine with new engine oil.


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12. Fill the cooling system with engine coolant.



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This article has been updated with TSB 02-06-01-003B, 4/15/08 This bulletin is being revised to include a Notice advising that the cylinder head bolts are NOT TO BE RE-USED. Please discardCorporate Bulletin Number 02-06-01-003A.

Cylinder Head Replacement - Left

- Tools Required - J 36660-A Torque Angle Meter

Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the engine coolant from the cooling system. 3. Drain the engine oil. 4. Lower the vehicle.

5. Remove the lower intake manifold. 6. Remove the exhaust crossover pipe. 7. Remove the thermostat bypass pipe. 8. Remove the right engine mount strut bracket. 9. Remove the oil level indicator tube. 10. Remove the engine left side spark plug wires from the spark plugs. 11. Remove the engine left side spark plugs. 12. Remove the engine left side exhaust manifold. 13. Remove the cylinder head bolts. 14. Remove the cylinder head. 15. Remove the cylinder head gasket.


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16. Clean the following areas: - The gasket sealing surfaces on the cylinder head, cylinder block, and intake manifolds - The cylinder block bolt threads - The cylinder head bolts


1. Install the cylinder head gasket.


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2. Install the cylinder head.


Notice: This component uses torque-to-yield bolts. When servicing this component, do not re-use the bolts. New torque-to-yield boltsmust be installed. Re-using used torque-to-yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW torque-to-yield bolts may lead to engine damage.

3. Install the NEW cylinder head bolts. - Tighten the NEW cylinder head bolts to 60 Nm (44 lb ft) in the order shown. Use the J 36660-A torque angle meter in order to rotatethe cylinder head bolts an additional 95 degrees.

4. Install the engine left side exhaust manifold. 5. Install the engine left side spark plugs. 6. Install the engine left side spark plug wires to the spark plugs. 7. Install the oil level indicator tube. 8. Install the right engine mount strut bracket. 9. Remove the thermostat bypass pipe. 10. Install the exhaust crossover pipe. 11. Install the lower intake manifold.


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12. Fill the engine with new engine oil. 13. Fill the cooling system with engine coolant.



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Documents

Exhaust Manifold Replacement - Right (M AP) (E GR) (EVAP)€¦ · Remove the Exhaust Gas Recirculation (E GR) valve. 7. Remove the ignition module and the ignition coils with the