78. Exhaust Manifold Installation - Left

1. Place the exhaust intermediate pipe (2) in position.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the intermediate pipe retaining stud at the cylinder head (3) and the bolt at the lower crankcase (1).
2.1. Tighten the intermediate pipe-to-lower crankcase retaining bolt (1) to 35 Nm (18 lb ft).
2.2. Tighten the intermediate pipe-to-cylinder head retaining stud (3) to 25 Nm (18 lb ft).





3. Hand start the EGR feed tube to intermediate pipe nut (1) to prevent crossthreading.
- Tighten the EGR feed tube-to-intermediate pipe nut to 60 Nm (44 lb ft).
4. Connect the EGR feed pipe flange (3) to the water crossover.
5. Install the EGR feed pipe to water crossover flange retaining bolt (3).
- Tighten the EGR feed tube to water crossover bolt to 25 Nm (18 lb ft).





6. Insert the end of the oil level indicator tube in the cylinder block. Align the mounting tab with the mounting bolt hole.
7. Install the oil level tube retaining bolt.
- Tighten the oil level tube retaining bolt to 10 Nm (89 lb in).
8. Install the oil level indicator.





9. If the engine is equipped with coolant heaters, install the left side (1) heater as follows:
9.1. Place the coolant heater (1) in position on the cylinder block.
9.2. Install the coolant heater retaining bolt.
- Tighten the coolant heater retaining bolt to 10 Nm (89 lb in).





10. With the manifold still on the bench, position a new manifold gasket (1) in place on the manifold sealing surface.
11. Install two outer manifold bolts (6) in the manifold to retain the gasket.
12. Install a new manifold to intermediate pipe flange gasket (5).
13. Using two hands, place the manifold (2) in the intermediate pipe and onto the cylinder head.
14. Install new manifold flange bolts (3) for maximum joint integrity. Hand tighten. Do not torque the flange bolts to specification until the engine is mounted in the vehicle.
15. Hand tighten the two outer manifold bolts.
16. Install the remaining manifold retaining bolts.
- Tighten the exhaust manifold retaining bolts (6) to 25 Nm (18 lb ft).





17. Coat the oxygen sensor threads with high temperature anti-seize, GM P/N 5613695 or equivalent.
18. Install the oxygen sensor (1).
- Tighten the oxygen sensor to 40 Nm (30 lb ft).