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Home >> Pontiac >> 2003 >> Aztek AWD >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Exhaust Manifold Replacement - Right >> Installation Procedure
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Installation Procedure

  1. If removed, install the Heated Oxygen Sensor (HO2S).
  2. If removed, install the exhaust gas recirculation (EGR) valve pipe.
  3. Raise and support the vehicle.
  4. Install the exhaust manifold gasket.
  5. Install the exhaust manifold.
  6. Install the exhaust manifold nuts.

    Tighten 

    Tighten the exhaust manifold nuts to 16 N.m (12 lb ft).

    Fig 1: Installing Right Exhaust Manifold And Gasket
    G01501619Courtesy of GENERAL MOTORS CORP.
  7. Install the exhaust manifold lower heat shield.
  8. Install the exhaust manifold upper heat shield.
  9. Install the exhaust manifold heat shield bolts.

    Tighten 

    Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).

  10. Install the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT  .
  11. Lower the vehicle.
  12. Install the exhaust crossover pipe. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT  .
  13. Install the exhaust crossover pipe heat shield. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT  .
  14. Connect the Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 2: Installing Right Upper And Lower Exhaust Manifold Heat Shields
    G01501620Courtesy of GENERAL MOTORS CORP.
  15. Install the EVAP solenoid bracket.
  16. Install the spark plug wires to the engine right bank spark plugs.
  17. Install the ignition module and the ignition coils with the bracket.
  18. Rotate the engine back to the original position. Refer to ROTATING THE ENGINE FOR SERVICE ACCESS .
  19. Install the EGR valve to the intake manifold.
  20. Install the MAP sensor.
  21. Install the accelerator cable bracket to the throttle body.
  22. Install the throttle body air inlet duct.
  23. Connect negative battery cable.
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