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HOMESERVICE MANUALSCHEVROLET2009TAHOE BASE, 4.8 CREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 78 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST MANIFOLD REPLACEMENT - RIGHT SIDEINSTALLATION PROCEDURE
2009 Chevrolet Tahoe Base, 4.8 C

Installation Procedure

2009 Chevrolet Tahoe Base, 4.8 CSECTION Installation Procedure
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2007 GMC Yukon XL, 2007 GMC Yukon, 2007 Chevrolet Tahoe, 2007 Chevrolet Suburban, and 2007 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT:
  • Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may affect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance.
  • The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material.
  • Do not apply sealant to the first 3 threads of the bolt.
    Fig 1: View Of Exhaust Manifold, Gasket & Bolts
    GM1708618Courtesy of GENERAL MOTORS CORP.
  1. Install the exhaust seal to the exhaust manifold.
  2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts.
  3. Position the NEW exhaust manifold gasket and exhaust manifold to the cylinder head.
    4. NOTE: Refer to Fastener Notice .
  4. Install the exhaust manifold bolts.

    Tighten: 

    1. Tighten the bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
    2. Tighten the bolts a final pass to 20 N.m (15 lb ft). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.

  5. Using a flat punch, bend the gasket tab at the rear of the gasket around the cylinder head edge.
    6. Fig 2: View Of Heater Inlet Hose, Clamp & Waterpump
    GM1697282Courtesy of GENERAL MOTORS CORP.
  6. If equipped with rear A/C perform the following steps, otherwise proceed to step 15.
  7. Position the inlet hose.
  8. Install the heater inlet hose (2) to the water pump.
  9. Position the heater inlet hose clamp (1) at the water pump.
    10. Fig 3: View Of Radiator Surge Tank Outlet Hose, Clamp & Water Pump
    GM1697283Courtesy of GENERAL MOTORS CORP.
  10. Position the outlet hose.
  11. Install the radiator surge tank outlet hose (2) to the water pump.
  12. Position the radiator surge tank outlet hose clamp at the water pump (1).
  13. Raise and support the vehicle.
    14. Fig 4: View Of Exhaust Manifold, Gasket & Catalytic Converter
    GM1708617Courtesy of GENERAL MOTORS CORP.
  14. Install the catalytic converter to exhaust manifold nuts. (1500 series shown, 2500 series similar).

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

  15. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) or Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) .
  16. Lower the vehicle.
  17. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  18. Install the spark plugs. Refer to Spark Plug Replacement .
  19. Install the ignition coils. Refer to Ignition Coil Replacement .
  20. Fill the cooling system. Refer to Draining and Filling Cooling System .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.