GrandPrix, Impala 2006-2008, Monte Carlo 2006-2007

Exhaust Manifold

Print

Removal & Installation



3.4L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner
     
    Throttle body air inlet duct
     
    Right engine mount strut bracket
     
    Exhaust crossover pipe heat shield
     
    Exhaust crossover pipe nuts to the left exhaust manifold
     
    Exhaust manifold heat shield
     
    Exhaust manifold
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 12 ft. lbs. (16 Nm)
     
    Exhaust manifold heat shield and torque the bolts to 89 inch lbs. (10 Nm)
     
    Crossover pipe and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Crossover pipe heat shield and torque the bolts to 89 inch lbs. (10 Nm)
     
    Right engine mount strut bracket
     
    Negative battery cable
     
    Throttle body air inlet duct
     
    Air cleaner
     

  2.  
  3. Start the vehicle and check for leaks, repair if necessary.
  4.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Throttle body air inlet duct
     
    Accelerator cable bracket from the throttle body
     

  4.  
  5. Rotate the engine for service access.

    Manifold Air Pressure (MAP) sensor
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Ignition module and the ignition coils with the bracket
     
    Spark plug wires from the plugs
     
    Heated Oxygen Sensor (HO 2 S) electrical connector
     
    Evaporative Emissions (EVAP) solenoid bracket
     
    Exhaust crossover heat shield
     
    Exhaust crossover pipe from the manifold
     
    Catalytic converter from the manifold
     
    Exhaust manifold heat shields
     
    Exhaust manifold
     

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the nuts to 12 ft. lbs. (16 Nm)
     
    Exhaust manifold heat shields and torque the bolts to 89 inch lbs. (10 Nm)
     
    Catalytic converter and torque the nuts to 24 ft. lbs. (32 Nm)
     
    Crossover pipe to the manifold and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Crossover pipe heat shield and torque the bolts to 89 inch lbs. (10 Nm)
     
    EVAP solenoid bracket
     
    HO 2 S electrical connector
     
    Spark plug wires from the plugs
     
    Ignition module, ignition coils and bracket
     
    EGR pipe
     
    MAP sensor
     

  2.  
  3. Rotate the engine back to the original position.

    Accelerator cable bracket to the throttle body
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

3.5L & 3.9L Engines
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel injector sight shield
     
    Engine mount strut and bracket
     
    Cooling fans
     
    Upper and lower radiator hoses
     
    Transaxle oil cooler lines from the radiator
     
    Radiator
     
    Alternator
     
    Exhaust manifold heat shield
     
    Oil level indicator tube
     
    Secondary Air Injection (AIR) control valve assembly from the engine mount strut bracket
     
    Exhaust manifold-to-crossover pipe studs
     
    Exhaust manifold
     

  6.  

To install:

  1. Install or connect the following:

    Manifold to the crossover pipe using a new gasket and torque the studs to 18 ft. lbs. (25 Nm)
     
    Exhaust manifold with a new gasket and torque the bolts to 18 ft. lbs. (25 Nm)
     
    AIR valve and torque the pipe nut to 44 ft. lbs. (60 Nm) and the bolt to 80 inch lbs. (9 Nm)
     
    Oil level indicator tube and torque the bolt to 80 inch lbs. (9 Nm)
     
    Exhaust manifold heat shield and torque the bolts to 80 inch lbs. (9 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Radiator and torque the bolts to 89 inch lbs. (10 Nm)
     
    Transaxle oil cooler lines and torque the fitting to 17 ft. lbs. (23 Nm)
     
    Upper and lower radiator hoses
     
    Cooling fans and torque the bolts to 89 inch lbs. (10 Nm)
     
    Engine mount strut bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Engine mount strut and torque the bolts to 35 ft. lbs. (48 Nm)
     
    Fuel injector sight shield and torque the nuts to 27 inch lbs. (3 Nm)
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fuel injector cover
     
    Air intake duct
     
    Engine mount strut
     
    Fuel lines from the supply rail
     
    Cruise control and accelerator cables from the throttle body
     
    Transaxle selector range cable and cable brackets
     
    Transaxle shift cable from the shift module
     
    Brake booster vacuum hose from the engine
     
    Wiring harness connectors from the engine and transaxle
     
    Upper radiator hose
     
    Transaxle oil cooler lines from the radiator
     
    Surge tank inlet hose
     
    Heater hoses from the engine
     
    Lower radiator air deflector
     
    Battery cables from the retainers
     
    Lower radiator hose
     
    A/C compressor without disconnecting the lines and move it aside
     
    Starter wiring
     
    Catalytic converter from the manifold
     
    Front wheels and splash shields
     
    Wheel Speed Sensor (WSS) wiring from the lower control arms
     
    Tie rod ends from the steering knuckles
     
    Lower ball joints from the knuckles
     
    Halfshafts
     
    Intermediate shaft from the steering rack
     

  8.  
  9. Secure the vehicle to the lift in preparation for engine removal.
  10.  
  11. Position an engine/frame support table under the vehicle and lower the vehicle to meet the table.
  12.  
  13. Remove or disconnect the following:

    Frame-to-body bolts
     
    Crossover pipe from the front manifold
     
    Exhaust Gas Recirculation (EGR) pipe from the crossover pipe
     
    Right exhaust manifold from the engine

    Click image to see an enlarged view

    Fig. Exploded view of the right exhaust manifold-3.5L engine

     

  14.  

To install:

  1. Install or connect the following:

    Right exhaust manifold with a new gasket and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Crossover pipe to the front exhaust manifold and torque the bolts to 18 ft. lbs. (25 Nm)
     
    EGR pipe to the crossover pipe and torque the pipe nut to 44 ft. lbs. (60 Nm)
     

  2.  
  3. Position the engine/transaxle assembly under the vehicle.
  4.  
  5. Coat the sub-frame bushings with rubber lubricant.
  6.  
  7. Lower the vehicle onto the assembly. Align the sub-frame on the vehicle using 2 bolts or drill bits, 3 / 4 inches thick by 8 inches long through the alignment holes on the right side of the frame.
  8.  
  9. Install new frame-to-body bolts. Torque the bolts to 133 ft. lbs. (180 Nm) starting with the rear bolts and then the front bolts.
  10.  
  11. Raise the vehicle and remove the frame table.
  12.  
  13. Install or connect the following:
    NOTE
    Be sure the shaft is fully seated on the stub before installing the pinch bolt.



    Intermediate shaft to the steering rack and torque the bolts to 35 ft. lbs. (48 Nm)
     



    Halfshafts
     
    Ball joints and torque the nuts to 40 ft. lbs. (55 Nm)
     
    Tie rod ends and torque the nuts to 22 ft. lbs. (30 Nm) plus an additional 120 degree turn
     
    WSS wiring harness
     
    Splash shields and front wheels
     
    Catalytic converter and torque the nuts to 53 inch lbs. (6 Nm)
     
    Starter wiring
     
    A/C compressor and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Lower radiator hose
     
    Battery cables in their retainers
     
    Lower radiator air deflector and torque the bolts to 15 ft. lbs. (20 Nm)
     

  14.  
  15. Remove the straps securing the vehicle to the lift.

    Heater hoses
     
    Surge tank hose
     
    Transaxle oil cooler lines to the radiator and torque the fittings to 17 ft. lbs. (23 Nm)
     
    Upper radiator hose
     
    Wiring harness connectors to the engine and transaxle
     
    Transaxle shift cable to the shift module and bracket
     
    Transaxle range selector cable
     
    Cruise control and accelerator cables to the throttle body
     
    Fuel lines to the supply rail
     
    Engine mount strut and torque the bolts to 35 ft. lbs. (48 Nm)
     
    Air inlet duct
     
    Fuel injector sight shield
     
    Negative battery cable
     

  16.  
  17. Refill the cooling system.
  18.  
  19. Start the engine and check for leaks, repair if necessary.
  20.  

3.8L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Fuel injector sight shield
     
    Engine mount struts
     
    Exhaust crossover from the manifold
     
    Spark plug wires from the plugs
     
    Oil level indicator tube
     
    Exhaust manifold heat shield
     
    Engine lift hook
     
    Exhaust manifold
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the left exhaust manifold mounting-3.8L engine

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Engine lift hook and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Exhaust manifold heat shield and torque the bolts to 15 ft. lbs. (20 Nm).
     
    Oil level indicator tube and torque the nut to 14 ft. lbs. (19 Nm)
     
    Spark plug wires
     
    Exhaust crossover and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Engine mount struts and torque the bolts to 35 ft. lbs. (48 Nm)
     
    Fuel injector sight shield
     
    Negative battery cable
     

  2.  
  3. Start the vehicle and check for leaks, repair if necessary.

    Click image to see an enlarged view

    Fig. Exploded view of the crossover pipe mounting-3.8L engine



    Click image to see an enlarged view

    Fig. Exploded view of the right exhaust manifold mounting-3.8L engine

  4.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Fuel injector sight shield
     
    Cross vehicle brace
     
    Exhaust crossover pipe from the right exhaust manifold
     
    AIR pipe, if equipped
     
    Exhaust manifold pipe stud nuts and the catalytic converter pipe from the right exhaust manifold
     
    Exhaust Gas Recirculation (EGR) adapter pipe from the manifold
     

  4.  
  5. Rotate the engine to access the right side of the engine.

    Heated Oxygen Sensor (HO 2 S) electrical connector
     
    Spark plug wires from the plugs
     
    Right engine lift bracket
     
    Fuel injector sight shield bracket
     
    Transaxle fluid filler tube
     
    Exhaust manifold
     

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Engine lift bracket and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Transaxle fluid filler tube
     
    Fuel injector sight shield bracket and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Spark plug wires
     
    Heated Oxygen Sensor (HO 2 S) electrical connector
     

  2.  
  3. Rotate the engine back to the original position.

    EGR adapter pipe and torque the bolt to 21 ft. lbs. (29 Nm)
     
    Catalytic converter and torque the bolts to 26 ft. lbs. (35 Nm)
     
    Exhaust crossover pipe and torque the bolts to 13 ft. lbs. (18 Nm)
     
    AIR pipe, if equipped
     
    Cross vehicle brace
     
    Fuel injector sight shield
     
    Negative battery cable
     

  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

5.3L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine sight shield.
  4.  
  5. Remove the exhaust crossover pipe heat shield in order to access the cross pipe to the exhaust manifold nuts.
  6.  
  7. Remove the exhaust crossover pipe nuts from the left exhaust manifold.
  8.  
  9. Remove the left side spark plugs.
  10.  
  11. Remove the oil level indicator tube.
  12.  
  13. Remove the exhaust manifold heat shield bolts (3).
  14.  
  15. Remove the exhaust manifold heat shield (2).
  16.  
  17. Remove the heater hose retainer bolts in order to be able to remove the manifold.
  18.  
  19. Remove the exhaust manifold bolts.
  20.  
  21. Remove the exhaust manifold (1).
  22.  
  23. Remove and discard the exhaust manifold gasket.
  24.  
  25. Clean and inspect the left exhaust manifold.

    Click image to see an enlarged view

    Fig. Left side exhaust manifold-5.3L engine

  26.  

To install:


WARNING
Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets my affect vehicle emissions and/or On Board Diagnostic (OBD) II system performance. The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. DO NOT apply threadlock to the first three thread of the bolts.

  1. Apply a 0.2 in. (5mm) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the threads of the exhaust manifold bolts.
  2.  
  3. Install a NEW exhaust manifold gasket, the exhaust manifold and bolts. Tighten as follows:

    Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the bolts beginning with the center 2 bolts. Alternate from side to side, and work toward the outside.
     
    Tighten the bolts a final pass to 15 ft. lbs. (20 Nm). Tighten the bolts beginning with the center 2 bolts. Alternate from side to side, and work toward the outside.
     

  4.  
  5. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.
  6.  
  7. Install the exhaust manifold heat shield (2).
  8.  
  9. Install the exhaust manifold heat shield bolts (3). Tighten the bolts to 9 Nm (80 inch lbs.).
  10.  
  11. Install the oil level indicator tube.
  12.  
  13. Install the left side spark plugs.
  14.  
  15. Install the exhaust crossover pipe nuts from the left exhaust manifold. Tighten the nuts to 18 ft. lbs. (25 Nm).
  16.  
  17. Install the exhaust crossover pipe heat shield.
  18.  
  19. Install the heater pipe retainer bolts. Tighten the bolts to 16 Nm (12 ft. lbs.).
  20.  
  21. Install the engine sight shield.
  22.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine sight shield.
  4.  
  5. Remove the spark plugs.
  6.  
  7. Remove the exhaust crossover pipe nuts from the right exhaust manifold.
    WARNING
    To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

  8.  
  9. Disconnect the catalytic converter from the exhaust manifold. Support the catalytic converter and exhaust system with the mechanics wire.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the ignition coil.
    WARNING
    Do not remove the pigtail from either the heated oxygen sensor (HO 2 S) or the oxygen sensor (O 2 S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO 2 S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor:



    Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance.
     
    Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems.
     
    Ensure the sensor or vehicle lead wires should not be bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire.
     
    Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance.
     
    Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed.
     

  14.  
  15. Remove the O 2 sensors.
  16.  
  17. Remove the exhaust manifold heat shield bolts.
  18.  
  19. Remove the exhaust manifold heat shield.
  20.  
  21. Remove the exhaust manifold bolts.
  22.  
  23. Remove the exhaust manifold.
  24.  
  25. Remove and discard the exhaust manifold gasket.
  26.  
  27. Clean and inspect the left exhaust manifold.
  28.  

To install:


WARNING
Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets my affect vehicle emissions and/or On Board Diagnostic (OBD) II system performance. The cylinder head exhaust manifold bolt hole threads must be clean and free of debris or threadlocking material. DO NOT apply threadlock to the first three threads of the bolts.

  1. Apply a 0.2 in. (5mm) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the threads of the exhaust manifold bolts.
  2.  
  3. Install a NEW exhaust manifold gasket, the exhaust manifold and bolts. Tighten as follows:

    Tighten the bolts a first pass to 15 Nm (11 ft. lbs.). Tighten the bolts beginning with the center 2 bolts. Alternate from side to side, and work toward the outside.
     
    Tighten the bolts a final pass to 15 ft. lbs. (20 Nm). Tighten the bolts beginning with the center 2 bolts. Alternate from side to side, and work toward the outside.
     

  4.  
  5. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the right cylinder head.
  6.  
  7. Install the exhaust manifold heat shield.
  8.  
  9. Install the exhaust manifold heat shield bolts. Tighten the bolts to 9 Nm (80 inch lbs.).
    NOTE
    A special anti-seize compound is used on the HO 2 S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation.

  10.  
  11. If re-installing the old sensor, coat the threads with anti-seize compound P/N 12377953, or equivalent.
  12.  
  13. Install the bank 1 sensor 1 to the exhaust manifold. Tighten the sensor to 42 Nm (31 ft. lbs.).
  14.  
  15. Connect the bank 1 sensor 1 electrical connector.
  16.  
  17. Install the CPA retainer.
  18.  
  19. Raise the vehicle.
  20.  
  21. Install NEW gaskets to the exhaust manifold and muffler studs.
  22.  
  23. Position the catalytic converter into place.
  24.  
  25. Install the catalytic converter hangers to the converter.
  26.  
  27. Install the catalytic converter pipe stud nuts. Tighten the nuts to 35 Nm (26 ft. lbs.).
  28.  
  29. Install the catalytic converter nuts. Tighten the nuts to 44 ft. lbs. (60 Nm).
  30.  
  31. Remove the exhaust system support.
  32.  
  33. Install the exhaust crossover pipe nuts to the right exhaust manifold. Tighten the nuts to 18 ft. lbs. (25 Nm).
  34.  
  35. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the ignition coil bolts.
  36.  
  37. Install the ignition coil(s), as necessary.
  38.  
  39. Install the ignition coil bolts, as necessary. Tighten the bolts to 8 Nm (71 inch lbs.).
  40.  
  41. Install the spark plug wire(s) to the ignition coil(s), as necessary.
  42.  
  43. Connect the left ignition coil main electrical connector.
  44.  
  45. Install the CPA retainer.
  46.  
  47. Install the spark plugs.
  48.  
  49. Install the fuel injector sight shield.
  50.  

 
label.common.footer.alt.autozoneLogo