Front Exhaust Manifold Replacement: Installation

Install exhaust manifold and new gasket.
Install lower exhaust manifold nuts.
Torque:

Exhaust Manifold Nut: 20 N.m (15 ft-lbs)

Fig 1: Installing Exhaust Manifold
Courtesy of GENERAL MOTORS CORP.
Install oil filter housing to block.
Torque:

Oil Filter Cartridge Housing-to-Engine: 45 N.m (33 ft-lbs)

Fig 2: Installing Oil Filter Housing
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Install oil filter cap and filter to housing.
Torque:

Oil Filter Cap: 15 N.m (11 ft-lbs)
Install front exhaust manifold pipe assembly and gaskets.
NOTE: Do not tighten fasteners.
Install front exhaust manifold pipe to rear exhaust manifold pipe bolts.

Fig 3: Connecting Front & Rear Exhaust Pipes
Courtesy of GENERAL MOTORS CORP.
Install front exhaust manifold pipe to exhaust manifold nuts.
Torque:

Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 30 N.m (25 ft-lbs)
Tighten front exhaust manifold pipe to rear exhaust manifold pipe bolts.
Torque:

Exhaust Manifold Pipe Bolts: 20 N.m (15 ft-lbs)

Fig 4: Bolting Front Exhaust Pipe To Exhaust Manifold
Courtesy of GENERAL MOTORS CORP.

Always use a nickle-based anti-seize compound Saturn P/N 21485279 (or equivalent) on the threads of the oxygen sensor. If the oxygen sensor is replaced, do not apply anti-seize to the new sensor. New sensors have anti-seize pre-applied. Never use silicon product; silicon products will cause damage to oxygen sensor.
Install front exhaust manifold pipe heated oxygen sensor.
Torque:

Oxygen Sensors (Lower Exhaust Pipe): 45 N.m (33 ft-lbs)

Fig 5: Installing HO2S Sensor
Courtesy of GENERAL MOTORS CORP.
Lower vehicle.
Connect front exhaust manifold pipe heated oxygen sensor electrical connection.
Install upper exhaust manifold nuts.
Torque:

Exhaust Manifold Nut: 20 N.m (15 ft-lbs)
Install power steering pipe bracket bolt.
Torque:

Power Steering Pipe Bracket Bolt: 8 N.m (71 in-lbs)

Fig 6: Installing Exhaust Manifold Nuts
Courtesy of GENERAL MOTORS CORP.
Install two new O-rings onto coolant extension housing.
Lubricate O-ring with coolant and install extension housing.

Fig 7: Installing Extension Housing
Courtesy of GENERAL MOTORS CORP.
Install oil level indicator tube and coolant extension housing bolt.
Torque:

Coolant Extension Housing Bolt: 20 N.m (15 ft-lbs)

Fig 8: Installing Coolant Extension Housing Bolt
Courtesy of GENERAL MOTORS CORP.
Lower powertrain and align front transaxle mount and mounting bracket using engine support fixture.
Install front transaxle mount through bolt.
Torque:

Transaxle Mount Through Bolt: 55 N.m (41 ft-lbs)

Fig 9: Installing Front Transaxle Mount Through Bolt
Courtesy of GENERAL MOTORS CORP.
Remove engine support fixture and adapters SA9150E and J43405 (or equivalent).

Fig 10: Removing Engine Support Fixture
Courtesy of GENERAL MOTORS CORP.
Install upper radiator hose.

Fig 11: Installing Upper Radiator Hose
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Refill coolant.

Fig 12: Refilling Coolant At Surge Tank
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Install exhaust manifold heated oxygen sensor using O2 sensor wrench J39194C.
Torque:

Oxygen Sensors (Exhaust Manifold): 50 N.m (37 ft-lbs)
Connect exhaust manifold heated oxygen sensor electrical connection.
Start vehicle and check for coolant and exhaust leaks.

Fig 13: Installing HO2S Sensor

Courtesy of GENERAL MOTORS CORP.