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Home >> GMC >> 2002 >> Jimmy 2D Utility, Part Time, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Exhaust Manifold Replacement - Left >> Installation Procedure

Installation Procedure

IMPORTANT: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and bolts in place.
  1. Sub-assemble the bolts, spark plug wire shields, and NEW gaskets to the exhaust manifold.

    The stud installs in the front hole.

  2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
    3. Fig 1: Tabs On Exhaust Manifold Gaskets
    G01660155Courtesy of GENERAL MOTORS CORP.
  3. From under the hood position the exhaust manifold by the engine.
  4. Raise the vehicle to the proper height.
  5. Working the wheelhouse opening, install the exhaust manifold.
  6. Install the spark plug wire shields.
  7. If reusing the fasteners, apply threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the threads of the exhaust manifold bolts and stud.
    NOTE: 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.
  8. Install the exhaust manifold bolts and stud.
    Fig 2: Exhaust Manifold Bolts And Stud
    G01660156Courtesy of GENERAL MOTORS CORP.

    Tighten 

    1. 8.1. Tighten the exhaust manifold bolts and stud on the first pass to 15 N.m (11 lb ft).
    2. 8.2. Tighten the exhaust manifold bolts and stud on the final pass to 30 N.m (22 lb ft).
  9. Install the spark plug wires to the spark plug wire retainers.
  10. Install the spark plug wires onto the spark plugs.
  11. Install the fender wheelhouse extension.
    12. Fig 3: Fender Wheelhouse Extension
    G01660157Courtesy of GENERAL MOTORS CORP.
  12. Install the front tire to. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  13. Raise the vehicle. Refer to LIFTING & JACKING THE VEHICLE in General Information.
  14. Connect the exhaust pipe to the exhaust manifold. Refer to Exhaust Manifold Pipe Replacement .
  15. Lower the vehicle.
  16. Connect the ECT sensor electrical connector.
    17. Fig 4: ECT Sensor Electrical Connector
    G01660158Courtesy of GENERAL MOTORS CORP.
  17. Install the radiator inlet hose support bracket and nut.
    Fig 5: Radiator Inlet Hose Support Bracket And Nut
    G01660159Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the radiator inlet hose support bracket nut to 36 N.m (27 lb ft).

  18. Install the intermediate steering shaft. Refer to INTERMEDIATE STEERING SHAFT REPLACEMENT - LOWER in Steering Wheel and Column.
    NOTE:
    • Handle the MAF sensor carefully.
    • Do not drop the MAF sensor in order to prevent damage to the MAF sensor.
    • Do not damage the screen located on the air inlet end of the MAF.
    • Do not touch the sensing elements.
    • Do not allow solvents and lubricants to come in contact with the sensing elements.
    • Use a small amount of a soap based solution in order to aid in the installation.
  19. Install air cleaner outlet duct to throttle body.
  20. Install air cleaner outlet duct to MAF sensor.
    21. Fig 6: Air Cleaner Outlet Duct To MAF Sensor
    G01660160Courtesy of GENERAL MOTORS CORP.
  21. Connect the IAT sensor harness connector.
    22. Fig 7: IAT Sensor Harness Connector
    G01660161Courtesy of GENERAL MOTORS CORP.
  22. Install the air cleaner outlet duct retaining wingnut.
    23. Fig 8: Air Cleaner Outlet Duct Retaining Wingnut
    G01660162Courtesy of GENERAL MOTORS CORP.
  23. Connect the breather tube to the air cleaner outlet duct.
    24. Fig 9: Breather Tube To Air Cleaner Outlet Duct
    G01660163Courtesy of GENERAL MOTORS CORP.
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