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For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2000 🢒 Grand Prix 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Exhaust Manifold Installation

Exhaust Manifold Installation Left Side


    Object Number: 54683 Size: SH
  1. Install the exhaust manifold gasket.
  2. Install the exhaust manifold.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the exhaust manifold studs and bolt.

    4. Tighten
    Tighten the exhaust manifold studs and the exhaust manifold bolt to 30 N·m (22 lb ft).

  4. Install the left side spark plugs.

    5. Tighten
    Tighten the left side spark plugs to 27 N·m (20 lb ft).


    Object Number: 154527 Size: SH
  5. Install the left engine lift hook.
  6. Install the left engine lift hook nut and bolt.

    7. Tighten
    Tighten the left engine lift hook nut and bolt to 30 N·m (22 lb ft).


    Object Number: 154529 Size: SH
  7. Install the left exhaust manifold heat shield.
  8. Install the left exhaust manifold heat shield nuts.

    9. Tighten
    Tighten the left exhaust manifold heat shield nuts to 20 N·m (15 lb ft).

Exhaust Manifold Installation Right Side


    Object Number: 36682 Size: SH
  1. Install the right exhaust manifold gasket.
  2. Install the right exhaust manifold.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the right exhaust manifold studs.

    4. Tighten
    Tighten the right exhaust manifold studs to 30 N·m (22 lb ft).


    Object Number: 395585 Size: SH
  4. Install the fuel injector sight shield cover bracket.
  5. Install the fuel injector sight shield cover bracket nuts.

    6. Tighten
    Tighten the fuel injector sight shield bracket nuts to 30 N·m (22 lb ft).


    Object Number: 154526 Size: SH
  6. Install the right engine lift hook.
  7. Install the right engine lift hook nut and bolt.

    8. Tighten
    Tighten the right engine lift hook nut and bolt to 30 N·m (22 lb ft).


    Object Number: 97747 Size: SH
  8. Install the lower right exhaust manifold heat shield.

    9. Object Number: 97750 Size: SH
  9. Install the upper right exhaust manifold heat shield.

    10. Object Number: 395584 Size: SH
  10. Install the heated oxygen sensor lead.

    11. Important: Inspect the EGR outlet pipe for leaks during installation. If leaks are present, replace the EGR adapter assembly.


    Object Number: 36667 Size: SH
  11. Install the EGR mounting bracket.
  12. Install the EGR mounting bracket bolts.

    13. Tighten
    Tighten the EGR mounting bracket bolts to 50 N·m (37 lb ft).

  13. Install the EGR inlet pipe to the exhaust manifold.
  14. Install the EGR inlet pipe bolt.

    15. Tighten
    Tighten the EGR inlet pipe bolt to 29 N·m (21 lb ft).

Exhaust Manifold Installation Right Side (NC8 California Emissions)


    Object Number: 540523 Size: SH
  1. Install the right exhaust manifold gasket.
  2. Install the right exhaust manifold.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the right exhaust manifold studs and nuts.

    4. Tighten
    Tighten the right exhaust manifold studs and nuts to 30 N·m (22 lb ft).

  4. Install the right side spark plugs.

    5. Tighten
    Tighten the right side spark plugs to 27 N·m (20 lb ft).


    Object Number: 347473 Size: SH
  5. Install the fuel injector sight shield cover bracket.
  6. Install the fuel injector sight shield cover bracket nuts.

    7. Tighten
    Tighten the fuel injector sight shield bracket nuts to 30 N·m (22 lb ft).


    Object Number: 154526 Size: SH
  7. Install the right engine lift hook.
  8. Install the right engine lift hook nut and bolt.

    9. Tighten
    Tighten the right engine lift hook nut and bolt to 30 N·m (22 lb ft).


    Object Number: 97747 Size: SH
  9. Install the lower right exhaust manifold heat shield.

    10. Object Number: 97750 Size: SH
  10. Install the upper right exhaust manifold heat shield.

    11. Object Number: 511603 Size: SH
  11. Intall air injection check valve.
  12. Install air injection check valve bolts.

    13. Tighten
    Tighten the air injection check valve bolts to 10 N·m (89 lb in).


    Object Number: 511608 Size: SH
  13. Install vacuum solenoid and lines.
  14. Install the vacuum solenoid bolt.

    15. Tighten
    Tighten the vacuum solenoid bolt to 10 N·m (89 lb in).


    Object Number: 540520 Size: SH
  15. Coat the threads of the heated oxygen sensor with anti-seize compond GM P/N 5613695, or equivalent.
  16. Install the heated oxygen sensor.

    17. Tighten
    Tighten the heated oxygen sensor to 42 N·m (31 lb ft).

  17. Install the heated oxygen sensor lead.

    18. Object Number: 511606 Size: SH
  18. Install air injection pipe.
  19. Install air injection pipe assembly nuts.

    20. Tighten
    Tighten the air injection pipe nuts to 10 N·m (89 lb in).

    Important: Inspect the EGR outlet pipe for leaks during installation. If leaks are present, replace the EGR adapter assembly.


    Object Number: 36667 Size: SH
  20. Install the EGR mounting bracket.
  21. Install the EGR mounting bracket bolts.

    22. Tighten
    Tighten the EGR mounting bracket bolts to 50 N·m (37 lb ft).

  22. Install the EGR inlet pipe to the exhaust manifold.
  23. Install the EGR inlet pipe bolt.

    24. Tighten
    Tighten the EGR inlet pipe bolt to 29 N·m (21 lb ft).