Installation Procedure

Important:  Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may effect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance.

The cylinder head exhaust manifold bolt hole threads must be cleaned and free of debris or threadlocking material.

1. If necessary, install the exhaust manifold heat shield and bolts.

   Tighten 

   Tighten the exhaust manifold heat shield bolts to 9 N.m (80 lb in).

2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953489), or equivalent to the threads of the exhaust manifold bolts.
   Fig 1: Exhaust Manifold Bolts

   Courtesy of GENERAL MOTORS CORP.
3. Position the exhaust manifold and a NEW gasket into place.
4. Install the exhaust manifold bolts.

   Tighten 

   1. 4.1. Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, working toward the outside bolts.
   2. 4.2. Tighten the exhaust manifold bolts a final pass to 25 N.m (18 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, working toward the outside bolts.
5. Bend over the exposed edge of the exhaust manifold gasket at the rear of the cylinder head.
6. Install the spark plugs. Refer to SPARK PLUGS in Engine Controls - 5.7 L.
7. Place the ignition coil bracket into place.
8. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the coil bracket studs.
9. Install the ignition coil bracket studs.

   Tighten 

   Tighten the ignition coil bracket studs to 12 N.m (106 lb in).

   Fig 2: Ignition Coil Bracket Studs

   Courtesy of GENERAL MOTORS CORP.
10. Install the brake booster vacuum hose to the brake booster.
    Fig 3: Installing Brake Booster Vacuum Hose To Brake Booster

    Courtesy of GENERAL MOTORS CORP.
11. Install the AIR pipe (with check valve) and a NEW gasket.
12. Install the AIR pipe bolts.

    Tighten 

    Tighten the AIR pipe bolts to 20 N.m (15 lb ft).

    Fig 4: AIR Pipe Bolts

    Courtesy of GENERAL MOTORS CORP.
13. Install the AIR pipe (2).
14. Install the AIR injection pipe hose (3) to the left check valve.
15. Install the AIR injection pipe hose (1) to the right check valve.
16. Install the hose clamps at the right and left check valves.
    Fig 5: Installing Air Injection Pipe Hose To Left & Right Check Valve

    Courtesy of GENERAL MOTORS CORP.
17. Install the AIR hose to the AIR pipe.
18. Install the hose clamp at the AIR pipe.
19. Raise the vehicle.
    Fig 6: Installing Hose Clamp At Air Pipe

    Courtesy of GENERAL MOTORS CORP.
20. Apply anti-sieze compound GM P/N 12377953 or equivalent to the threads of the oxygen sensor.
    NOTE: Refer to OXYGEN SENSOR NOTICE in Cautions and Notices.
21. Install the oxygen sensor.

    Tighten 

    Tighten the oxygen sensor to 42 N.m (30 lb ft).

22. Install the oxygen sensor connector clip at the body.
23. Connect the oxygen sensor electrical connector.
24. Install the CPA lock.
    Fig 7: Connecting Oxygen Sensor Electrical Connector

    Courtesy of GENERAL MOTORS CORP.
25. Install the exhaust manifold nuts.

    Tighten 

    Tighten the exhaust manifold nuts to 20 N.m (15 lb ft).

26. Lower the vehicle.
27. Install the generator. Refer to GENERATOR in Engine Electrical.
    Fig 8: Exhaust Manifold Nuts

    Courtesy of GENERAL MOTORS CORP.
28. Install the fuel rail cover.
    Fig 9: Fuel Rail Cover

    Courtesy of GENERAL MOTORS CORP.