GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Uplander Ext. 🢒 Preface 🢒 Dangers, Warnings, and Cautions 🢒 Exhaust Manifold Replacement - Right Side

Removal Procedure

    Object Number: 1679874 Size: SH
  1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  2. Remove the generator. Refer to Generator Replacement .
  3. Remove the ignition coil. Refer to Ignition Coil Replacement .
  4. Disconnect the engine harness electrical connector (4) from the heated oxygen sensor (HO2S).

    5. Object Number: 1618175 Size: SH

    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.
  6. Disconnect the heater hose from the heater pipes.
  7. Remove the nuts holding the heater pipes onto the throttle body.
  8. Position the heater pipes out of the way.

    9. Object Number: 1679427 Size: SH
  9. Remove the exhaust crossover pipe heat shield bolts (1) and shield (2).

    10. Object Number: 1679429 Size: SH
  10. Remove the exhaust crossover pipe (2) to exhaust manifold nuts (1).
  11. Remove the catalytic converter. Refer to Catalytic Converter Replacement .

    12. Object Number: 1618181 Size: SH
  12. Remove the exhaust manifold heat shield bolts.
  13. Remove the exhaust manifold heat shield.

    14. Object Number: 1618188 Size: SH
  14. Remove the exhaust manifold bolts.
  15. Remove the exhaust manifold.
  16. Remove the exhaust manifold gasket.

Installation Procedure

    Object Number: 1618188 Size: SH
  1. Position a NEW exhaust manifold gasket to the cylinder head.
  2. Install the exhaust manifold.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the exhaust manifold bolts and tighten to 20 N·m (15 lb ft) .

    4. Object Number: 1618181 Size: SH
  4. Install the exhaust manifold heat shield.
  5. Install the exhaust manifold heat shield bolts and tighten to 10 N·m (89 lb in) .
  6. Install the catalytic converter. Refer to Catalytic Converter Replacement .

    7. Object Number: 1679429 Size: SH
  7. Install the exhaust crossover pipe (2) to exhaust manifold nuts (1) and tighten to 20 N·m (15 lb ft) .

    8. Object Number: 1679427 Size: SH
  8. Install the exhaust crossover pipe heat shield (2) and bolts (1) and tighten to 10 N·m (89 lb in) .
  9. Position the heater pipes back to the original position.
  10. Install the nut holding the heater pipes onto the throttle body.
  11. Connect the heater hoses to the heater pipes.

    12. Object Number: 1618175 Size: SH

    Note: 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 and tighten to 42 N·m (31 lb ft) .

    13. Object Number: 1679874 Size: SH
  13. Connect the engine harness electrical connector (4) to the HO2S.
  14. Install the ignition coil. Refer to Ignition Coil Replacement .
  15. Install the generator. Refer to Generator Replacement .
  16. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .