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Home >> GMC >> 2003 >> Jimmy 2D Utility, Part Time, Standard >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Exhaust Manifold Replacement >> Installation Procedure

Installation Procedure

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  1. Install the heat shield and bolts to the exhaust manifold, if removed.

    Tighten 

    Tighten the heat shield bolts to 12 N.m (106 lb in).

    Fig 1: Installing Heat Shield Bolts
    G01979386Courtesy of GENERAL MOTORS CORP.
  2. Install the exhaust manifold gasket and exhaust manifold.
  3. Install the exhaust manifold nuts.

    Tighten 

    Tighten the exhaust manifold nuts to 13 N.m (115 lb in).

    Fig 2: Installing Exhaust Manifold Nuts
    G01979387Courtesy of GENERAL MOTORS CORP.
  4. Install the air injection pipe with gasket.

    Tighten 

    • Tighten the air injection pipe nut (1) to 13 N.m (115 lb in).
    • Tighten the air injection pipe nut (2) to 10 N.m (89 lb in).
  5. Install the oxygen sensor, if removed. Refer to HEATED OXYGEN SENSOR in System and Component Testing - 2.2L in Engine Performance.
  6. Install the oil level indicator tube. Refer to OIL LEVEL INDICATOR AND TUBE REPLACEMENT .
    Fig 3: Installing Air Injection Pipe With Gasket
    G01979388Courtesy of GENERAL MOTORS CORP.
  7. Install the power steering pump.
    1. 7.1. Loosely install the power steering pump to accessory mounting bracket 3 bolts.
    2. 7.2. Loosely install the 2 nuts holding the power steering pump bracket to the cylinder head studs.
    3. 7.3. Loosely install the power steering pump lower bracket bolt.
  8. Tighten the fasteners in the following sequence:

    Tighten 

    1. 8.1. Tighten the accessory mounting bracket 3 bolts to 30 N.m (22 lb ft).
    2. 8.2. Tighten the cylinder head stud 2 nuts to 50 N.m (37 lb ft).
    3. 8.3. Tighten the lower bracket bolt to 50 N.m (37 lb ft).
  9. Install the air conditioning compressor, if equipped. Refer to COMPRESSOR REPLACEMENT (2.2L) or COMPRESSOR REPLACEMENT (4.3L) in Heating, Ventilation and Air Conditioning.
    Fig 4: Installing Exhaust Pipe To Exhaust Manifold
    G01979389Courtesy of GENERAL MOTORS CORP.
  10. Raise the vehicle. Refer to JACKING AND LIFTING in General Information.
  11. Install the exhaust pipe to the exhaust manifold. Refer to Exhaust Manifold Pipe Replacement  on .
  12. Lower the vehicle.
  13. Install the drive belt. Refer to DRIVE BELT REPLACEMENT .
  14. Install the upper fan shroud. Refer to FAN SHROUD REPLACEMENT in Engine Cooling.
  15. Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
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