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For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Impala 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Exhaust Manifold Installation - Right Side

Exhaust Manifold Installation - Right Side C, H, W


    Object Number: 683928 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install the exhaust manifold studs.

    2. Tighten
    Tighten the exhaust manifold studs to 10 N·m (89 lb in).


    Object Number: 683924 Size: SH
  2. Install the exhaust manifold gasket.
  3. Install the exhaust manifold.
  4. Install the exhaust manifold bolts and nuts.

    5. Tighten
    Tighten the exhaust manifold bolts and nuts to 30 N·m (22 lb ft).

  5. Install the right side spark plugs.

    6. Tighten

        • Tighten the spark plugs to 27 N·m (20 lb ft) when installing the spark plugs in to a new cylinder head.
        • Tighten the spark plugs to 15 N·m (13 lb ft) when re-installing the spark plugs after initial installation.

    Object Number: 97747 Size: SH
  6. Install the lower right exhaust manifold heat shield.

    7. Object Number: 97750 Size: SH
  7. Install the upper right exhaust manifold heat shield.

    8. Object Number: 347473 Size: SH
  8. Install the fuel injector sight shield cover bracket.
  9. Install the fuel injector sight shield cover bracket nuts.

    10. Tighten
    Tighten the fuel injector sight shield bracket nuts to 30 N·m (22 lb ft).


    Object Number: 154526 Size: SH
  10. Install the right engine lift hook.
  11. Install the right engine lift hook nut and bolt.

    12. Tighten
    Tighten the right engine lift hook nut and bolt to 30 N·m (22 lb ft).


    Object Number: 347468 Size: SH
  12. Coat the threads of the heated oxygen sensor with anti-seize compound.
  13. Install the heated oxygen sensor.

    14. Tighten
    Tighten the heated oxygen sensor to 42 N·m (31 lb ft).

  14. Install the heated oxygen sensor lead.

    15. Object Number: 36667 Size: SH

    Important: Inspect the EGR outlet pipe for leaks during installation. If leaks are present, replace the EGR adapter assembly.

  15. Install the EGR valve adapter to cylinder head.
  16. Install the EGR valve adapter to cylinder head bolts.

    17. Tighten
    Tighten the EGR valve adapter to cylinder head bolts to 50 N·m (37 lb ft).

  17. Install the EGR inlet pipe to the exhaust manifold.
  18. Install the EGR inlet pipe bolt.

    19. Tighten
    Tighten the EGR inlet pipe bolt to 29 N·m (21 lb ft).

  19. Install the EGR outlet pipe to EGR valve adapter.
  20. Install the EGR outlet pipe to EGR valve adapter nut.

    21. Tighten
    Tighten the EGR outlet pipe to EGR valve adapter nut to 29 N·m (21 lb ft).

Exhaust Manifold Installation - Right Side C, H, W with NC8


    Object Number: 683928 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install the exhaust manifold studs.

    2. Tighten
    Tighten the exhaust manifold studs to 10 N·m (89 lb in).


    Object Number: 540523 Size: SH
  2. Install the exhaust manifold gasket.
  3. Install the exhaust manifold.
  4. Install the exhaust manifold bolts and nuts.

    5. Tighten
    Tighten the exhaust manifold bolts and nuts to 30 N·m (22 lb ft).

  5. Install the right side spark plugs.

    6. Tighten

        • Tighten the spark plugs to 27 N·m (20 lb ft) when installing the spark plugs in to a new cylinder head.
        • Tighten the spark plugs to 15 N·m (13 lb ft) when re-installing the spark plugs after initial installation.

    Object Number: 683944 Size: SH
  6. Install the lower right exhaust manifold heat shield.

    7. Object Number: 683939 Size: SH
  7. Install the upper right exhaust manifold heat shield.

    8. Object Number: 683936 Size: SH
  8. Install the right engine lift hook.
  9. Install the right engine lift hook nut and bolt.

    10. Tighten
    Tighten the right engine lift hook nut and bolt to 30 N·m (22 lb ft).


    Object Number: 683931 Size: SH
  10. Install the fuel injector sight shield cover bracket.
  11. Install the fuel injector sight shield cover bracket nuts.

    12. Tighten
    Tighten the fuel injector sight shield cover bracket nuts to 30 N·m (22 lb ft).


    Object Number: 511603 Size: SH
  12. Install the air injection check valve.
  13. Install the air injection check valve bolts.

    14. Tighten

        • Tighten the air injection check valve bolt (1) to 25 N·m (18 lb ft).
        • Tighten the air injection check valve bolts (2) to 10 N·m (89 lb in).

    Object Number: 511608 Size: SH
  14. Install the vacuum solenoid and vacuum lines.
  15. Install the vacuum solenoid bolt.

    16. Tighten
    Tighten the vacuum solenoid bolt to 10 N·m (89 lb in).


    Object Number: 540520 Size: SH
  16. Coat the threads of the heated oxygen sensor with anti-seize compound.
  17. Install the heated oxygen sensor.

    18. Tighten
    Tighten the heated oxygen sensor to 42 N·m (31 lb ft).

  18. Install the heated oxygen sensor lead.

    19. Object Number: 511606 Size: SH
  19. Install the air injection pipe.
  20. Install the air injection pipe assembly nuts.

    21. Tighten
    Tighten the air injection pipe assembly nuts to 10 N·m (89 lb in).


    Object Number: 36667 Size: SH

    Important: Inspect the EGR outlet pipe for leaks during installation. If leaks are present, replace the EGR adapter assembly.

  21. Install the EGR valve adapter to cylinder head.
  22. Install the EGR valve adapter to cylinder head bolts.

    23. Tighten
    Tighten the EGR valve adapter to cylinder head bolts to 50 N·m (37 lb ft).

  23. Install the EGR inlet pipe to the exhaust manifold.
  24. Install the EGR inlet pipe bolt.

    25. Tighten
    Tighten the EGR inlet pipe bolt to 29 N·m (21 lb ft).

  25. Install the EGR outlet pipe to EGR valve adapter.
  26. Install the EGR outlet pipe to EGR valve adapter nut.

    27. Tighten
    Tighten the EGR outlet pipe to EGR valve adapter nut to 29 N·m (21 lb ft).

Exhaust Manifold Installation - Right Side F


    Object Number: 683957 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install the exhaust manifold studs.

    2. Tighten
    Tighten the exhaust manifold studs to 10 N·m (89 lb in).


    Object Number: 589366 Size: SH
  2. Install the exhaust manifold gasket to the cylinder head.
  3. Install the exhaust manifold to the cylinder head.
  4. Install the exhaust manifold nuts.

    5. Tighten
    Tighten the nuts to 23 N·m (17 lb ft).

  5. Install the right side spark plugs.

    6. Tighten

        • Tighten the spark plugs to 27 N·m (20 lb ft) when installing the spark plugs into a new cylinder head.
        • Tighten the spark plugs to 15 N·m (13 lb ft) when re-installing the spark plugs after initial installation.

    Object Number: 683970 Size: SH
  6. Install the exhaust manifold heat shield.
  7. Install the exhaust manifold heat shield nuts and bolt.

    8. Tighten

        • Tighten the 2 heat shield nuts to 23 N·m (17 lb ft).
        • Tighten the heat shield bolt to 10 N·m (89 lb in).