Exhaust Manifold Replacement - Right Side LD8

Special Tools

J 42640 Steering Column Anti-Rotation Pin

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 Steering Column Anti-Rotation Pin into the underside of the steering column.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
6. Remove the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement.
7. Remove the AIR check valve. Refer to Secondary Air Injection Check Valve Replacement.



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 from the lower control arms.




Warning: Failure to disconnect intermediate shaft from rack and pinion stub shaft can result in damage to steering gear and/or intermediate shaft. This damage can cause loss of steering control which could result in 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. Remove the right engine mount to frame nut.



17. Remove the left engine mount to frame nut.



18. Remove the transaxle mount to frame nuts.



19. Support the rear of the frame with a tall screw type jack.



20. Remove the 4 rearward engine frame-to-body bolts (1) (left side shown, right side similar).
21. Lower the screw type jack approximately 4 cm (1.5 in) allowing the rear of the engine frame to lower.



22. Remove the HO2S.



23. Remove the exhaust manifold nuts.
24. Remove the exhaust manifold (2).
25. Remove and discard the exhaust manifold gasket (1).

1. Install a NEW exhaust manifold gasket (1) onto the cylinder head studs.
2. Install exhaust manifold (2).

Caution: Refer to Fastener Caution in the Preface section.

3. Install the exhaust manifold nuts and tighten to 25 N·m (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 and tighten to 41 N·m (30 lb ft).



6. Raise the engine frame into position.
7. Install the 4 rearward engine frame-to-body bolts (1) (left side shown, right side similar) and tighten to 191 N·m (141 lb ft).



8. Remove the screw type jack.



9. Install the transaxle mount to frame nuts and tighten to 50 N·m (37 lb ft).



10. Install the left engine mount to frame nut and tighten to 80 N·m (59 lb ft).



11. Install the right engine mount to frame nut and tighten to 80 N·m (59 lb ft).




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.

12. Connect the intermediate shaft to the steering gear.
13. Install the intermediate shaft pinch bolt and tighten to 45 N·m (33 lb ft).
14. Install the intermediate shaft seal.



15. Connect the electronic suspension position sensor link ball studs to the lower control arms.



16. Install the steering gear heat shield.
17. Install the steering gear heat shield bolts and tighten to 9 N·m (80 lb in).



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



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



23. Remove the J 42640 Steering Column Anti-Rotation Pin .



24. Connect the engine harness electrical connector (2) to the HO2S.
25. Install the HO2S clip (5) to the AIR valve hose bracket.
26. Install the CPA retainer (3).

Exhaust Manifold Replacement - Right Side LZ9 or LGD

Tools Required

J 39194-B Heated Oxygen Sensor Wrench

1. Reposition the power steering reservoir. Refer to Power Steering Fluid Reservoir Replacement.



2. Remove the connector position assurance (CPA) retainer (3).
3. Disconnect the heated oxygen sensor (HO2S) electrical connector (2).
4. Remove the HO2S clip (1) from the ignition coil bracket.




Note: The HO2S uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

5. Remove the HO2S using the J 39194-B Heated Oxygen Sensor Wrench .



6. Remove the exhaust manifold shield bolts.
7. Remove the exhaust manifold shield.



8. Remove the exhaust crossover pipe heat shield bolts.
9. Remove the exhaust crossover pipe heat shield.



10. Remove the exhaust crossover pipe to right exhaust manifold nuts.



11. Remove the upper exhaust manifold bolts.
12. Remove the catalytic converter. Refer to Catalytic Converter Replacement.
13. Remove the lower exhaust manifold bolts.
14. Remove the exhaust manifold.
15. Remove and discard the exhaust manifold gasket.

1. Install a NEW exhaust manifold gasket onto the cylinder head studs.
2. Install the exhaust manifold.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the lower exhaust manifold bolts and tighten to 20 N·m (15 lb ft)..
4. Install the catalytic converter. Refer to Catalytic Converter Replacement.
5. Lower the vehicle.
6. Install the upper exhaust manifold bolts and tighten to 20 N·m (15 lb ft)..



7. Install the exhaust crossover pipe to right exhaust manifold nuts.



8. Install the exhaust crossover pipe heat shield.
9. Install the exhaust crossover pipe heat shield bolts.



10. Install the exhaust manifold shield.
11. Install the exhaust manifold shield bolts and tighten to 10 N·m (89 lb in).




Important: Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound such as GM P/N 5613695 (or equivalent).

12. Install the HO2S using J 39194-B Heated Oxygen Sensor Wrench and tighten to 42 N·m (31 lb ft).



13. Connect the HO2S electrical connector (2).
14. Install the CPA retainer (3).
15. Install the HO2S clip (1) to the ignition coil bracket.
16. Install the power steering reservoir. Refer to Power Steering Fluid Reservoir Replacement.