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Home >> GMC >> 2004 >> Jimmy 2D Utility, Part Time, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Exhaust Manifold Replacement - Left >> Installation Procedure

Installation Procedure

    Fig 1: View Of Tabs On Exhaust Manifold Gasket
    GM476818Courtesy of GENERAL MOTORS CORP.
    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. From under the hood position the exhaust manifold by the engine.
  4. Raise the vehicle to the proper height.
    5. Fig 2: Installing Exhaust Manifold
    GM188045Courtesy of GENERAL MOTORS CORP.
  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.
    8. NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the exhaust manifold bolts and stud.

    Tighten: 

    1. Tighten the exhaust manifold bolts and stud on the first pass to 15 N.m (11 lb ft).
    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. Fig 3: View Of Fender Wheelhouse Extension
    GM303008Courtesy of GENERAL MOTORS CORP.
  11. Install the fender wheelhouse extension.
  12. Install the front tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  13. Raise the vehicle. Refer to Lifting and 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. Fig 4: Locating Engine Coolant Temperature Sensor Electrical Connector
    GM246797Courtesy of GENERAL MOTORS CORP.
  16. Connect the ECT sensor electrical connector.
    17. Fig 5: View Of Radiator Inlet Hose Support Bracket & Nut
    GM341247Courtesy of GENERAL MOTORS CORP.
  17. Install the radiator inlet hose support bracket and nut.

    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.
    19. 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.

    Fig 6: View Of Air Cleaner Outlet Duct
    GM424556Courtesy of GENERAL MOTORS CORP.
  19. Install air cleaner outlet duct to throttle body.
  20. Install air cleaner outlet duct to MAF sensor.
    21. Fig 7: Locating IAT Sensor Harness Connector
    GM10940Courtesy of GENERAL MOTORS CORP.
  21. Connect the IAT sensor harness connector.
    22. Fig 8: Locating Air Cleaner Outlet Duct Retaining Wingnut
    GM312278Courtesy of GENERAL MOTORS CORP.
  22. Install the air cleaner outlet duct retaining wingnut.
    23. Fig 9: View Of Breather Tube
    GM444792Courtesy of GENERAL MOTORS CORP.
  23. Connect the breather tube to the air cleaner outlet duct.
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