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For 1990-2009 cars only

Exhaust Manifold Replacement - Right Side RPO LD8

Tools Required

J 42640 Steering Column Anti-Rotation Pin

Removal Procedure

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.


    Object Number: 1665457  Size: SH
  1. Remove the connector position assurance (CPA) retainer (3).
  2. Disconnect the engine harness electrical connector (2) from the heated oxygen sensor (HO2S) .
  3. Remove the HO2S clip (5) from the secondary air injection (AIR) valve hose bracket.

  4. Object Number: 333146  Size: SH

    Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.

  5. Lock the steering column by installing the J 42640 into the underside of the steering column.
  6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  7. Remove the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .
  8. Remove the AIR check valve. Refer to Secondary Air Injection Check Valve Replacement .

  9. Object Number: 1663209  Size: SH
  10. Disconnect the engine harness clip (2) from the steering gear heat shield.

  11. Object Number: 1665450  Size: SH
  12. Disconnect the engine harness clip (3) from the steering gear heat shield.

  13. Object Number: 1670593  Size: SH
  14. Remove the steering gear heat shield bolts.
  15. Remove the steering gear heat shield.

  16. Object Number: 1665080  Size: SH
  17. Disconnect the electronic suspension position sensor link ball studs from the lower control arms.

  18. Object Number: 1665092  Size: SH

    Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

  19. Unsnap and remove the intermediate shaft seal.
  20. Remove the intermediate shaft pinch bolt.
  21. Separate the intermediate shaft from the steering gear.

  22. Object Number: 1665467  Size: SH
  23. Remove the right engine mount to frame nut.

  24. Object Number: 1665465  Size: SH
  25. Remove the left engine mount to frame nut.

  26. Object Number: 1670595  Size: SH
  27. Remove the transaxle mount to frame nuts.

  28. Object Number: 694208  Size: SH
  29. Support the rear of the frame with a tall screw type jack.

  30. Object Number: 1665303  Size: SH
  31. Remove the 4 rearward engine frame-to-body bolts (1) (left side shown, right side similar).
  32. Lower the screw type jack approximately 4 cm (1.5 in) allowing the rear of the engine frame to lower.

  33. Object Number: 1670529  Size: SH
  34. Remove the HO2S.

  35. Object Number: 1670474  Size: SH
  36. Remove the exhaust manifold nuts.
  37. Remove the exhaust manifold (2).
  38. Remove and discard the exhaust manifold gasket (1).

Installation Procedure


    Object Number: 1670474  Size: SH
  1. Install a NEW exhaust manifold gasket (1) onto the cylinder head studs.
  2. Install exhaust manifold (2).
  3. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the exhaust manifold nuts.
  5. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).


    Object Number: 1670529  Size: SH
  6. If reusing the old HO2S, coat the threads with anti-seize compound, GM P/N 12377953 or equivalent.
  7. Install the HO2S.
  8. Tighten
    Tighten the sensor to 41 N·m (30 lb ft).


    Object Number: 1665303  Size: SH
  9. Raise the engine frame into position.
  10. Install the 4 rearward engine frame-to-body bolts (1) (left side shown, right side similar).
  11. Tighten
    Tighten the bolts to 191 N·m (141 lb ft).


    Object Number: 694208  Size: SH
  12. Remove the screw type jack.

  13. Object Number: 1670595  Size: SH
  14. Install the transaxle mount to frame nuts.
  15. Tighten
    Tighten the nuts to 50 N·m (37 lb ft).


    Object Number: 1665465  Size: SH
  16. Install the left engine mount to frame nut.
  17. Tighten
    Tighten the nuts to 80 N·m (59 lb ft).


    Object Number: 1665467  Size: SH
  18. Install the right engine mount to frame nut.
  19. Tighten
    Tighten the nuts to 80 N·m (59 lb ft).


    Object Number: 1665092  Size: SH

    Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

  20. Connect the intermediate shaft to the steering gear.
  21. Install the intermediate shaft pinch bolt.
  22. Tighten
    Tighten the bolt to 45 N·m (33 lb ft).

  23. Install the intermediate shaft seal.

  24. Object Number: 1665080  Size: SH
  25. Connect the electronic suspension position sensor link ball studs to the lower control arms.

  26. Object Number: 1670593  Size: SH
  27. Install the steering gear heat shield.
  28. Install the steering gear heat shield bolts.
  29. Tighten
    Tighten the bolts to 9 N·m (80 lb in).


    Object Number: 1665450  Size: SH
  30. Connect the engine harness clip (3) to the steering gear heat shield.

  31. Object Number: 1663209  Size: SH
  32. Connect the engine harness clip (2) to the steering gear heat shield.
  33. Install the AIR check valve. Refer to Secondary Air Injection Check Valve Replacement .
  34. Install the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .
  35. Lower the vehicle.

  36. Object Number: 333146  Size: SH
  37. Remove the J 42640 .

  38. Object Number: 1665457  Size: SH
  39. Connect the engine harness electrical connector (2) to the HO2S.
  40. Install the HO2S clip (5) to the AIR valve hose bracket.
  41. Install the CPA retainer (3).

Exhaust Manifold Replacement - Right Side RPO L26

Removal Procedure

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.


    Object Number: 1687609  Size: SH
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  2. Remove the right side spark plugs. Refer to Spark Plug Replacement .
  3. Remove the secondary air injection (AIR) shutoff and check valve, if equipped. Refer to Secondary Air Injection Shutoff and Check Valve Replacement .
  4. Disconnect the engine harness electrical connector from the heated oxygen sensor (HO2S).
  5. Remove the HO2S pigtail clip from the sight shield bracket.

  6. Object Number: 1688501  Size: SH
  7. Remove the HO2S (1) from the exhaust manifold.

  8. Object Number: 153575  Size: SH
  9. Remove the power brake booster heat shield nuts.
  10. Remove the power brake booster heat shield.

  11. Object Number: 1688417  Size: SH
  12. Remove the studs attaching the exhaust crossover to the right exhaust manifold.
  13. Remove the transaxle fill tube. Refer to Transmission Fluid Filler Tube and Seal Replacement .
  14. Remove the catalytic converter. Refer to Catalytic Converter Replacement .

  15. Object Number: 1686569  Size: SH
  16. Remove the sight shield bracket nuts and bracket.

  17. Object Number: 1686568  Size: SH
  18. Remove the right engine lift bracket bolt and nut.
  19. Remove the engine lift bracket.

  20. Object Number: 1688306  Size: SH
  21. Remove the exhaust manifold heat shield bolts and shield.

  22. Object Number: 1688504  Size: SH
  23. Remove the exhaust gas recirculation (EGR) vale adapter pipe bolt.

  24. Object Number: 1688305  Size: SH
  25. Remove the exhaust manifold studs and nuts.
  26. Remove the exhaust manifold.
  27. Remove and discard the exhaust manifold gasket.
  28. Remove and discard the exhaust crossover pipe seal from the either the exhaust crossover or the manifold.

Installation Procedure


    Object Number: 1688305  Size: SH
  1. Install a NEW exhaust crossover pipe seal to the exhaust manifold.
  2. Install a NEW exhaust manifold gasket.
  3. Install the exhaust manifold.
  4. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the exhaust manifold studs and nuts.
  6. Tighten

        • Tighten the studs to 30 N·m (22 lb ft).
        • Tighten the nuts to 25 N·m (18 lb ft).

    Object Number: 1688504  Size: SH
  7. Install the EGR valve adapter pipe bolt.
  8. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 1688306  Size: SH
  9. Position the exhaust manifold heat shield.
  10. Install the exhaust manifold heat shield bolts.
  11. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 1686568  Size: SH
  12. Install the engine lift bracket.
  13. Install the right engine lift bracket bolt and nut.
  14. Tighten
    Tighten the bolt/nut to 25 N·m (18 lb ft).


    Object Number: 1686569  Size: SH
  15. Install the sight shield bracket nuts and bracket.
  16. Tighten
    Tighten the nuts to 30 N·m (22 lb ft).


    Object Number: 1688417  Size: SH
  17. Install the catalytic converter. Refer to Catalytic Converter Replacement .
  18. Install the transaxle fill tube. Refer to Transmission Fluid Filler Tube and Seal Replacement .
  19. Install the studs attaching the exhaust crossover to the right exhaust manifold.
  20. Tighten
    Tighten the studs to 18 N·m (13 lb ft).


    Object Number: 153575  Size: SH
  21. Install the power brake booster heat shield.
  22. Install the power brake booster heat shield nuts.
  23. Tighten
    Tighten the nuts to 20 N·m (15 lb ft).


    Object Number: 1688501  Size: SH

    Important: A special anti-seize compound is used on the HO2S 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 the reinstallation.

  24. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
  25. Install the HO2S (1) to the exhaust manifold.
  26. Tighten
    Tighten the sensor to 42 N·m (31 lb ft).


    Object Number: 1687609  Size: SH
  27. Connect the engine harness electrical connector to the HO2S.
  28. Install the HO2S pigtail clip to the sight shield bracket.
  29. Install the AIR shutoff and check valve, if equipped. Refer to Secondary Air Injection Shutoff and Check Valve Replacement .
  30. Install the right side spark plugs. Refer to Spark Plug Replacement .
  31. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .