Special Tools

J 42640 Steering Column Lock Pin

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.

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.

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.




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



8. Disconnect the engine harness clip (2) from the steering gear heat shield.



9. Disconnect the engine harness clip (3) from the steering gear heat shield.



10. Remove the steering gear heat shield bolts.
11. Remove the steering gear heat shield.



12. Disconnect the electronic suspension position sensor link ball studs (1) from the lower control arms.




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.

13. Unsnap and remove the intermediate shaft seal.
14. Remove the intermediate shaft pinch bolt.
15. Separate the intermediate shaft from the steering gear.



16. Support the rear of the frame with a tall screw type jack.



17. Remove the 4 rearward engine frame-to-body bolts (1).
18. Lower the screw type jack approximately 4 cm (1.5 in) allowing the rear of the engine frame to lower.



19. Remove the HO2S.



20. Remove the exhaust manifold nuts.
21. Remove the exhaust manifold (2).
22. Remove and discard the exhaust manifold gasket (1).

1. Install a NEW exhaust manifold gasket (1) onto the cylinder head studs.
2. Install the exhaust manifold (2).

Notice: Refer to Fastener Notice in the Preface section.

3. Install the exhaust manifold nuts.

Tighten
Tighten the nuts to 25 N·m (18 lb ft).




4. If reusing the old HO2S, coat the threads with anti-sieze compound, GM P/N 12377953 or equivalent.
5. Install the HO2S.

Tighten
Tighten the sensor to 41 N·m (30 lb ft).




6. Raise the engine frame into position.
7. Install the 4 rearward engine frame-to-body bolts (1).

Tighten
Tighten the bolts to 191 N·m (141 lb ft).




8. Remove the screw type jack.




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.

9. Connect the intermediate shaft to the steering gear.
10. Install the intermediate shaft pinch bolt.

Tighten
Tighten the bolt to 45 N·m (33 lb ft).

11. Install the intermediate shaft seal.



12. Connect the electronic suspension position sensor link ball studs (1) to the lower control arms.



13. Install the steering gear heat shield.
14. Install the steering gear heat shield bolts.

Tighten
Tighten the bolts to 9 N·m (80 lb in).




15. Connect the engine harness clip (3) to the steering gear heat shield.



16. Connect the engine harness clip (2) to the steering gear heat shield.
17. Install the AIR check valve. Refer to Secondary Air Injection Check Valve Replacement .
18. Install the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .
19. Lower the vehicle.



20. Remove the J 42640 from the steering column.



21. Connect the engine harness electrical connector (2) to the HO2S.
22. Install the HO2S clip (5) to the AIR valve hose bracket.
23. Install the CPA retainer (3).