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Home >> Pontiac >> 2004 >> GTO Automatic >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Exhaust Manifold Replacement - Left >> Installation Procedure

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 removed, position the heat shield to the exhaust manifold.
    2. Fig 1: View Of Exhaust Manifold Heat Shield & Retaining Bolt
    GM1340970Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the heat shield to exhaust manifold bolts.

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

    3. Fig 2: View Of Exhaust Manifold & Bolt
    GM1340968Courtesy of GENERAL MOTORS CORP.
  3. Position the exhaust manifold and new gasket to the cylinder head.
    4. IMPORTANT: Do not apply thread sealant to the first 3 threads of the exhaust manifold bolts.
  4. Apply a 5 mm (0.2 in) wide band of threadlocker GM P/N 12345493 (Canadian P/N 10953488), or equivalent, to the threads of the exhaust manifold bolts.
  5. Progressively torque the exhaust manifold bolts from the center to the outsides using 2 steps.

    Tighten: 

    1. Tighten the exhaust manifold bolts first pass to 15 N.m (11 lb ft).
    2. Tighten the exhaust manifold bolts second pass to 25 N.m (18 lb ft).

  6. Bend over the exposed edge of the exhaust manifold gasket at the rear of the cylinder head.
  7. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls.
  8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  9. Install the exhaust manifold to exhaust pipe flange nuts.

    Tighten:  Tighten the exhaust manifold to exhaust pipe flange nuts to 25 N.m (18 lb ft).

    10. Fig 3: View Of Coolant Temperature Sensor
    GM1340966Courtesy of GENERAL MOTORS CORP.
  10. Lower the vehicle, then install the coolant temperature sensor (1).

    Tighten:  Torque the coolant temperature sensor to 20 N.m (15 lb ft).

  11. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
    12. Fig 4: Identifying Air Intake Components
    GM1293684Courtesy of GENERAL MOTORS CORP.
  12. Position the intake duct then install 2 intake duct clamps (3).
  13. Connect the IAT sensor electrical connector (2).
  14. Connect the MAF sensor electrical connector (1).
  15. Install the fuel rail cover.
  16. Install the front suspension support brace. Refer to Front Suspension Support Brace Replacement in Front Suspension.
    17. CAUTION: Refer to Exhaust Service Caution in Cautions and Notices.
    CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  17. Connect the negative battery cable.
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