GM Corvette 1984-1996 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



5.7L (VIN 8) Engine

See Figures 1 and 2

Right side-1984-88 vehicles
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Drain the engine cooling system into a suitable container.
  6.  
  7. For 1985-88 vehicles, remove the plenum extension.
  8.  
  9. For 1985-88 vehicles, remove the EGR pipe bolts from the intake manifold.
  10.  
  11. Unfasten the rear A/C compressor brace, then allow the brace to hang at the compressor.
  12.  
  13. For 1985-88 vehicles, disconnect the dipstick tube from the manifold, then remove the dipstick.
  14.  
  15. Disconnect the AIR hose from the exhaust check valve and the converter pipe check valve.
  16.  
  17. For 1984 vehicles, detach the heater hose from the rear of the intake.
  18.  
  19. For 1985-88 vehicles, detach the wire at the temperature sending unit.
  20.  
  21. Tag and disconnect the spark plug wires from the plugs, and at the valve cover.
  22.  
  23. Remove the spark plugs, after the engine has cooled.
  24.  
  25. For 1984 vehicles, remove the temperature sending unit from the right head.
  26.  
  27. Raise and safely support the vehicle.
  28.  
  29. For 1984 vehicles, perform the following:
    1. Disconnect the exhaust pipe from the manifold.
    2.  
    3. Detach the AIR pipe from the exhaust manifold.
    4.  
    5. Unfasten the 2 rear exhaust manifold mounting bolts.
    6.  
    7. Separate the dipstick tube from the manifold.
    8.  
    9. Carefully lower the vehicle.
    10.  
    11. Unfasten the remaining manifold bolts. Remove the exhaust manifold.
    12.  

  30.  
  31. For 1985-88 vehicles, perform the following:
    1. Raise and safely support the vehicle.
    2.  
    3. Remove the catalytic converter AIR pipe clamp from the manifold.
    4.  
    5. Detach the exhaust crossover pie from both manifolds.
    6.  
    7. Remove the bolts from the catalytic converter front hanger.
    8.  
    9. Remove the catalytic converter AIR pipe.
    10.  
    11. Carefully lower the vehicle.
    12.  
    13. Unfasten the exhaust manifold mounting bolts. Remove the manifold and EGR pipe assembly.
    14.  
    15. If replacing the manifold, install the EGR pipe and clamp on the new manifold.
    16.  

  32.  
  33. Remove and discard the manifold gaskets. Thoroughly clean the gasket mating surfaces.
  34.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the exhaust manifold mounting-1984 5.7L (VIN 8) engines



Click image to see an enlarged view

Fig. Fig. 2: Exhaust manifold attachment-1985-88 vehicles shown, later years similar

To install:
  1. Place new gaskets in position, then install the manifold and secure with the mounting bolts. It may be necessary to install the 2 rear bolts with the vehicle raised. Tighten the bolts to 20 ft. lbs. (27 Nm).
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. For 1984 vehicles, attach the dipstick tube to the manifold.
  6.  
  7. For 1985-88 vehicles, install the AIR pipe with a new clamp and install the bolts at the converter hanger.
  8.  
  9. Connect the converter AIR pipe to the manifold.
  10.  
  11. Attach the exhaust pipe/crossover pipe to the manifold.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Install the temperature sending unit.
  16.  
  17. Install the spark plugs, then attach the wires, as tagged during removal. Make sure the wires are properly routed.
  18.  
  19. If removed, attach the heater hose.
  20.  
  21. Connect the AIR hose, or install the AIR check valve, as applicable.
  22.  
  23. For 1985-88 vehicles, attach the dipstick tube to the manifold and install the dipstick.
  24.  
  25. Install the A/C compressor brace.
  26.  
  27. For 1985-88 vehicles, install the EGR pipe bolts and the manifold, and connect the sensor wire.
  28.  
  29. For 1985-88 vehicles, install the plenum extension.
  30.  
  31. Install the air cleaner assembly.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Fill the cooling system with the proper type and amount of coolant.
  36.  

right side-1989-91 vehicles
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the EGR valve pipe and position it aside.
  4.  
  5. Unfasten the A/C compressor brace.
  6.  
  7. Remove the oil level indicator and guide tube.
  8.  
  9. Remove the AIR check valve from the manifold.
  10.  
  11. Detach the electrical connector from the temperature sending unit.
  12.  
  13. Tag and disconnect the spark plug wires from the plugs, unroute from the retainers.
  14.  
  15. Remove the spark plugs, after the engine has cooled.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Remove the AIR pipe clamp from the manifold.
  20.  
  21. Unfasten the front crossover pipe-to-manifold flange nuts, from the left and right sides.
  22.  
  23. Carefully lower the vehicle.
  24.  
  25. Unfasten the exhaust manifold mounting bolts, then remove the manifold. Remove and discard the gaskets, then thoroughly clean the gasket mating surfaces.
  26.  

To install:
  1. Position new gaskets, then install the exhaust manifold and secure with the mounting bolts. Tighten the bolts to 19 ft. lbs. (26 Nm).
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Install the left and right side front crossover pipe-to-manifold flange nuts and tighten to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the AIR pipe clamp on the manifold.
  8.  
  9. Carefully lower the vehicle.
  10.  
  11. Install the spark plugs, connect the wires and install the retainers.
  12.  
  13. Attach the electrical connector to the temperature sending unit.
  14.  
  15. Install the AIR check valve to the manifold.
  16.  
  17. Attach the guide tube and oil level indicator.
  18.  
  19. Install the A/C compressor brace.
  20.  
  21. Connect the EGR valve pipe.
  22.  
  23. Connect the negative battery cable.
  24.  

LEFT SIDE-1984-91 VEHICLES

See Figures 3, 4, 5, 6, 7, 8 and 9

  1. Remove the air cleaner assembly.
  2.  
  3. Remove the PCV hose from the intake and rocker cover.
  4.  
  5. Detach the AIR hose from the exhaust check valve.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: Unfasten the retaining screws...



Click image to see an enlarged view

Fig. Fig. 4: ... then disconnect the AIR hose from the exhaust check valve

  1. Disconnect the rear alternator brace from the manifold, then let the brace hang from the alternator.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: The rear alternator brace is secured with a bolt at the top and a nut at the bottom

  1. For 1989-91 vehicles,
    1. Tag and disconnect the spark plug wires from the plugs, unroute from the retainers.
    2.  
    3. Remove the spark plugs, after the engine has cooled.
    4.  

  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. For vehicles through 1988, disconnect the exhaust pipe from the manifold.
  6.  



Click image to see an enlarged view

Fig. Fig. 6: Top view of the exhaust manifold, after the pipe is disconnected

  1. For 1989-91 vehicles, unfasten the left and right side front crossover pipe-to-manifold flange nuts.
  2.  
  3. Carefully lower the vehicle.
  4.  



Click image to see an enlarged view

Fig. Fig. 7: You will probably have to move the check valve pipe aside in order to remove the exhaust manifold

  1. Remove the exhaust manifold. Remove and discard the manifold gaskets. Thoroughly clean the gasket mating surfaces.
  2.  



Click image to see an enlarged view

Fig. Fig. 8: Use a scraper to carefully clean the mating surfaces of the manifold



Click image to see an enlarged view

Fig. Fig. 9: Also, make sure to thoroughly clean the head-to-manifold mating surfaces

To install:
  1. Place new gaskets in position, then install the manifold and secure with the mounting bolts. Tighten the bolts to 20 ft. lbs. (27 Nm) for 1984-88 vehicles. For 1989-91 vehicles, tighten the bolts to 19 ft. lbs. (26 Nm).
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Attach the exhaust pipe to the manifold, or the crossover pipe-to-manifold flange nuts. Tighten the nuts to 15 ft. lbs. (20 Nm).
  6.  
  7. Carefully lower the vehicle.
  8.  
  9. For 1989-91 vehicles, install the spark plugs, connect the wires and install the retainers.
  10.  
  11. Fasten the alternator brace.
  12.  
  13. Connect the AIR hose.
  14.  
  15. Attach the PCV hose.
  16.  
  17. Install the air cleaner assembly.
  18.  
  19. Connect the negative battery cable.
  20.  

5.7L (VIN J) Engines
right side-1990-91 vehicles

See Figure 10

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the wheelhouse lower rear and center panels.
  4.  
  5. Unfasten the bolt retaining the oil level indicator and guide tube to the exhaust manifold, then remove the indicator/tube assembly from the vehicle.
  6.  
  7. Unfasten the front exhaust manifold-to-cylinder head bolts.
  8.  
  9. Remove the stud nut from the center of the manifold.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Detach the converter oxygen sensor electrical connector. In order to access the connector, the following steps may be necessary:
    1. Remove the bolts from the right front of the oil pan, securing the ignition timing sensor/oxygen sensor connector bracket.
    2.  
    3. Slide the connector/bracket assembly to the rear.
    4.  

  14.  
  15. Remove the AIR hose from the manifold.
  16.  
  17. Unfasten the screws retaining the center head shields, then remove the shields from the vehicle.
  18.  
  19. Remove the bolts securing the manifold/converter flanges to the exhaust pipe flanges.
  20.  
  21. Remove the bolts at the rear, holding the manifold to the head; remove the gasket and the manifold/converter assembly from the vehicle. Discard the gasket(s).
  22.  
  23. If the manifold is being replaced, transfer the oxygen sensors and heat shields to the new manifold.
  24.  
  25. Thoroughly clean the manifold and head mating surfaces.
  26.  



Click image to see an enlarged view

Fig. Fig. 10: The exhaust manifold/converter assembly is removed as a single unit-1990-91 and early 1992 5.7L (VIN J) engine

To install:
  1. Position the manifold/converter assembly to the engine. Install the bolts securing the manifold/converter flanges to the exhaust pipe flanges. Finger-tighten the bolts.
  2.  
  3. Carefully lower the vehicle.
  4.  
  5. Install the manifold gasket on the head.
  6.  
  7. Install the bolts at front, holding the manifold to the head. Finger-tighten the bolts.
  8.  
  9. If the stud at the center of the manifold was removed, or is loose, clean the threads then apply Loctite® 620 to the threads. Tighten the stud to 11 ft. lbs. (15 Nm).
  10.  
  11. Install the stud nut at the center of the manifold and finger-tighten the nut.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Instlal the bolts at the rear, securing the manifold to the head. Tighten the manifold rear bolts to 11 ft. lbs. (15 Nm) and the exhaust pipe flange bolts to 15 ft. lbs. (20 Nm).
  16.  
  17. Install the converter head shields and screws.
  18.  
  19. Attach the electrical connector to the converter oxygen sensor. If the oxygen sensor bracket was removed, tighten the oil pan bolts to 19 ft. lbs. (26 Nm).
  20.  
  21. Connect the air hose to the manifold.
  22.  
  23. Carefully lower the vehicle.
  24.  
  25. Tighten the manifold front bolts and stud nut to 11 ft. lbs. (15 Nm).
  26.  
  27. Install the wheel house lower rear and center panels.
  28.  

right side-1992-95 vehicles

See Figure 11

Early and late production vehicles in the 1992 vehicles utilized 2 different exhaust manifolds.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle. Remove the wheel and tire assembly.
  4.  
  5. Remove the wheel house lower rear and center panels.
  6.  
  7. On early 1992 models, remove the center stud nut.
  8.  
  9. On late 1992 and 1993-95 models, remove the manifold outer heat shields.
  10.  
  11. Remove the exhaust system assembly.
  12.  
  13. Remove the engine block heat shield.
  14.  
  15. On late 1992, and 1993-95 models, remove the catalytic converter from the manifold.
  16.  
  17. Detach the oxygen sensor connector.
  18.  
  19. On early 1992 models, remove the converter heat shields.
  20.  
  21. Remove the rear exhaust manifold bolts, spacers and nuts.
  22.  
  23. Carefully lower the vehicle.
  24.  
  25. Remove the AIR check valve and hose from the manifold.
  26.  
  27. Unfasten the bolt retaining the oil level indicator guide tube.
  28.  
  29. Remove the oil level indicator tube from the engine.
  30.  
  31. Remove the remaining exhaust manifold bolts and spacers.
  32.  
  33. Remove the exhaust manifold and gasket from the vehicle. Discard the gasket. If installing a new manifold, transfer the oxygen sensor and heat shields to the new manifold.
  34.  
  35. Thoroughly clean the manifold and cylinder head mating surfaces.
  36.  



Click image to see an enlarged view

Fig. Fig. 11: View of the exhaust manifolds used on late 1992 and 1993-95 vehicles-5.7L (VIN J) engines

To install:
  1. Position a new gasket, then install the manifold to the engine.
  2.  
  3. Install the front and center manifold bolts and spacers.
  4.  
  5. Install the oil level indicator tube.
  6.  
  7. Tighten the manifold bolts to 18 ft. lbs. (24 Nm).
  8.  
  9. Install the AIR check valve and hoses.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Install the rear manifold bolts, spacers and nuts. Tighten the bolts and nuts to 18 ft. lbs. (24 Nm).
  14.  
  15. If removed, install the converter heat shields.
  16.  
  17. Attach the oxygen sensor electrical connector.
  18.  
  19. If removed, install the catalytic converter and bolts to the manifold. Tighten the bolts to 17 ft. lbs. (23 Nm).
  20.  
  21. Install the engine block heat shield.
  22.  
  23. Install the exhaust system.
  24.  
  25. If removed, install the manifold outer heat shields.
  26.  
  27. Carefully lower the vehicle.
  28.  
  29. If removed, install the center stud nut and tighten to 18 ft. lbs. (24 Nm).
  30.  
  31. Install the wheel house lower rear and center panels.
  32.  
  33. Install the wheel and tire assembly
  34.  
  35. Connect the negative battery cable.
  36.  

left side-1990-91 vehicles
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the wheelhouse lower rear and center panels.
  4.  
  5. Disconnect the AIR hose from the exhaust manifold.
  6.  
  7. Unfasten the bolts retaining the manifold to the head.
  8.  
  9. Remove the stud nut from the center, retaining the manifold to the head.
  10.  
  11. Unfasten the bolts holding the manifold to the head. Remove the gasket from the manifold.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Detach the converter oxygen sensor electrical connector.
  16.  
  17. Unfasten the heat shield retaining screws, then remove the heat shields.
  18.  
  19. Unfasten the bolts retaining the manifold/converter flange to the front exhaust pipe flange. Remove the manifold/converter from the vehicle.
  20.  
  21. If the manifold is being replaced, transfer the oxygen sensors and heat shields to the new manifold.
  22.  
  23. Thoroughly clean the manifold and head mating surfaces.
  24.  

To install:
  1. Position the manifold/converter assembly to the engine. Install the bolts securing the manifold/converter flanges to the exhaust pipe flanges. Finger-tighten the bolts.
  2.  
  3. Carefully lower the vehicle.
  4.  
  5. Install the manifold gasket on the head.
  6.  
  7. Install the bolts securing the manifold to the cylinder head. Finger-tighten the bolts.
  8.  
  9. If the stud at the center of the manifold was removed, or is loose, clean the threads then apply Loctite® 620 to the threads. Tighten the stud to 11 ft. lbs. (15 Nm).
  10.  
  11. Install the stud nut at the center of the manifold and finger-tighten the nut.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Tighten the exhaust pipe flange bolts and tighten to 15 ft. lbs. (20 Nm).
  16.  
  17. Install the heat shields and secure with the retaining screws.
  18.  
  19. Attach the electrical connectors to the converter oxygen sensors.
  20.  
  21. Carefully lower the vehicle.
  22.  
  23. Attach the AIR hose onto the exhaust manifold.
  24.  
  25. Install the wheel house lower rear and center panels.
  26.  
  27. Connect the negative battery cable.
  28.  

LEFT SIDE-1992-95 vehicles
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle. Remove the wheel and tire assembly.
  4.  
  5. Remove the wheel house lower rear and center panels.
  6.  
  7. Remove the exhaust system assembly.
  8.  
  9. Remove the left floor pan heat shield.
  10.  
  11. Remove he left heat shield from the frame.
  12.  
  13. Remove the engine block heat shield.
  14.  
  15. Detach the oxygen sensor electrical connector.
  16.  
  17. On early 1992 vehicles, remove the converter heat shields.
  18.  
  19. Remove the AIR check valves, houses and pipe.
  20.  
  21. On late 1992, and 1993-95 vehicles, remove the manifold outer heat shield.
  22.  
  23. On late 1992, and 1993-95 vehicles, remove the catalytic converter from the manifold.
  24.  
  25. Remove the exhaust manifold bolts, spacers and nut.
  26.  
  27. On early 1992 vehicles, remove the center stud nut.
  28.  
  29. Remove the exhaust manifold and gasket from the vehicle. Discard the gasket. If installing a new manifold, transfer the oxygen sensor and heat shields to the new manifold.
  30.  
  31. Thoroughly clean the manifold and cylinder head mating surfaces.
  32.  

To install:
  1. Position a new gasket, then install the manifold to the engine.
  2.  
  3. Install the manifold bolts, spacers and nut.
  4.  
  5. If removed, install the center stud nut.
  6.  
  7. Tighten the bolts and nut to 18 ft. lbs. (24 Nm).
  8.  
  9. If removed, install the catalytic converter and bolts to the manifold and tighten to 17 ft. lbs. (23 Nm).
  10.  
  11. The remainder of installation is the reverse of the removal procedure.
  12.  
  13. Install the wheel house lower rear and center panels.
  14.  
  15. Install the wheel and tire assembly
  16.  
  17. Connect the negative battery cable.
  18.  

5.7L (VIN P and 5) Engines

See Figures 12 and 13

right side
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. On 1993-96 convertibles, remove the underbody crossbrace.
  6.  
  7. Remove the catalytic converter from the exhaust manifold.
  8.  
  9. For 1993-96 vehicles, remove the complete exhaust system.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. Remove the fuel rail covers.
  14.  
  15. Detach the wiring harness connectors from the fuel injectors.
  16.  
  17. Disconnect the vacuum hose from the fuel pressure regulator.
  18.  
  19. Unfasten the fuel rail mounting bolts, then remove the fuel injectors and fuel rail from the manifold.
  20.  
  21. Tag and disconnect the spark plug wires from the spark plugs, then unfasten the wire clips from the supports.
  22.  
  23. Remove the spark plugs.
  24.  
  25. Remove the front spark plug bracket and bolt.
  26.  
  27. Remove the oil level indicator and tube.
  28.  
  29. Disconnect the AIR pipe (secondary air injection), then remove he gasket and check valve as an assembly from the intake and exhaust manifolds and cylinder head.
  30.  



Click image to see an enlarged view

Fig. Fig. 12: View of the secondary air injection valve and related components-1995 vehicle shown, other years similar

  1. Unfasten the exhaust manifold studs and bolts, then remove the heat shields, exhaust manifold and gasket. Discard the gasket and replace with new ones during installation. Thoroughly clean the gasket mating surfaces. For 1995-96 vehicles, clean the exhaust manifold bolt holes with a 3 / 8 in. tag, then flush the holes with a suitable cleaning solvent.
  2.  



Click image to see an enlarged view

Fig. Fig. 13: Exploded view of the exhaust manifold assemblies-5.7L (VIN P and 5 engines)

To install:
  1. Position a new gasket, then install the exhaust manifold and heat shields. For 1995-96 vehicles, apply a 1 / 4 in. (8mm) band of suitable adhesive to the bolt threads.
  2.  
  3. For Install the retaining studs and bolts, then tighten to the following specifications:
    1. 1993 vehicles: 26 ft. lbs. (35 Nm)
    2.  
    3. 1994 vehicles: 35 ft. lbs. (47 Nm)
    4.  
    5. 1995 vehicles: 26 ft. lbs. (35 Nm)
    6.  
    7. 1996 vehicles: 30 ft. lbs. (40 Nm).
    8.  

  4.  
  5. Install the AIR pipe, gasket and check valve and secure with the mounting bolts. Tighten the AIR pipe fitting-to-exhaust manifold to 25 ft. lbs. (34 Nm). Tighten the bracket bolt to 25 ft. lbs. (34 Nm). Tighten the AIR pipe flange bolts to 19 ft. lbs. (26 Nm).
  6.  
  7. Apply a suitable sealant around the oil level indicator tube, about 1 / 2 in. (13mm) below the bead. Install the oil level indicator and tube to the cylinder block.
  8.  
  9. Install the front spark plug bracket and bolt. Install the spark plugs. Tighten the bracket bolts to 105 inch lbs. (12 Nm), and the spark plugs to 11 ft. lbs. (15 Nm).
  10.  
  11. Attach the spark plug wires and retaining clips.
  12.  
  13. Install the fuel injector and rail assembly to the intake manifold. Install the mounting bolts and tighten to 15 ft. lbs. (20 Nm).
  14.  
  15. Connect the vacuum hose to the fuel pressure regulator, and attach the wiring harness connectors to the fuel pressure regulator.
  16.  
  17. Install the fuel rail covers.
  18.  
  19. Raise and safely support the vehicle.
  20.  
  21. If removed, install the complete exhaust system.
  22.  
  23. Install the catalytic converter to the exhaust manifold and secure with the retaining nuts. Tighten the nuts to 15 ft. lbs. (21 Nm).
  24.  
  25. On 1993-96 convertibles, install the underbody crossbrace.
  26.  
  27. Carefully lower the vehicle, then connect the negative battery cable.
  28.  

left side
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. On 1993-96 convertibles, remove the underbody crossbrace.
  6.  
  7. Remove the catalytic converter from the exhaust manifold.
  8.  
  9. For 1993-96 vehicles, remove the complete exhaust system.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. Remove the air intake duct.
  14.  
  15. Remove the serpentine drive belt.
  16.  
  17. For 1992 vehicles, remove the left wheel well center panel.
  18.  
  19. For 1993-96 vehicles, remove the ASR adjuster from the wheel well center panel and position it aside.
  20.  
  21. For 1992 vehicles, remove the A/C compressor/alternator top brace. Unbolt the A./C compressor and position it aside. Do NOT disconnect the refrigerant lines.
  22.  
  23. For 1993-96 vehicles, unbolt and reposition the alternator and A/C compressor. Do NOT disconnect the refrigerant lines from the compressor.
  24.  
  25. Remove the AIR pipe, check valve and hose as an assembly from the exhaust manifold.
  26.  
  27. Tag and disconnect the spark plug wires from the plugs, then detach the wire clips from the supports.
  28.  
  29. Remove the A/C compressor and accessory bracket braces.
  30.  
  31. Remove the spark plug wire supports, then remove the spark plugs.
  32.  
  33. Unfasten the exhaust manifold studs and bolts. Remove the heat shields, and the exhaust manifold and gasket.
  34.  
  35. Discard the gasket and thoroughly clean the gasket mating surfaces. For 1995-96 vehicles, clean the exhaust manifold bolt holes with a 3 / 8 in. tag, then flush the holes with a suitable cleaning solvent.
  36.  

To install:
  1. Position a new gasket, then install the exhaust manifold and heat shields. For 1995-96 vehicles, apply a 1 / 4 in. (8mm) band of suitable adhesive to the bolt threads.
  2.  
  3. For Install the retaining studs and bolts, then tighten to the following specifications:
    1. 1993 vehicles: 26 ft. lbs. (35 Nm)
    2.  
    3. 1994 vehicles: 35 ft. lbs. (47 Nm)
    4.  
    5. 1995 vehicles: 26 ft. lbs. (35 Nm)
    6.  
    7. 1996 vehicles: 30 ft. lbs. (40 Nm)
    8.  

  4.  
  5. Install the spark plug and secure with the spark plug supports. Tighten the spark plugs to 11 ft. lbs. (15 Nm) and the wire supports to 105 inch lbs. (12 Nm).
  6.  
  7. Install the A/C compressor and accessory bracket braces to the exhaust manifold.
  8.  
  9. Connect the spark plug wires and install the retaining clips.
  10.  
  11. Install the AIR pipe, check valve and hose assembly. Tighten the AIR pipe fitting-to-exhaust manifold to 25 ft. lbs. (34 Nm).
  12.  
  13. For 1993-96 vehicles, install the compressor and alternator.
  14.  
  15. For 1992 vehicles, install the A/C compressor and the compressor and alternator top brace.
  16.  
  17. Install the left wheel well center panel or ASR adjuster assembly, as applicable.
  18.  
  19. Install the serpentine drive belt and the air intake duct.
  20.  
  21. Raise and safely support the vehicle.
  22.  
  23. If removed, install the complete exhaust system.
  24.  
  25. Install the catalytic converter to the exhaust manifold and secure with the retaining nuts. Tighten the nuts to 15 ft. lbs. (21 Nm).
  26.  
  27. On 1993-96 convertibles, install the underbody crossbrace.
  28.  
  29. Carefully lower the vehicle.
  30.  
  31. Connect the negative battery cable.
  32.  

 
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