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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1556 (Engine Exhaust System - 5.7L) >> Repair Instructions >> Exhaust Manifold Replacement - Left >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Tighten the exhaust manifold bolts as specified in the service procedure. Improperly installed and/or leaking exhaust manifold gaskets may effect vehicle emissions and/or On-Board Diagnostics (OBD) II system performance.

The cylinder head exhaust manifold bolt hole threads must be cleaned and free of debris or threadlocking material.

    Fig 1: Left Exhaust Manifold, Bolts & Gasket
    GM639834Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  1. If necessary, install the exhaust manifold heat shield and bolts.

    Tighten:  Tighten the exhaust manifold heat shield bolts to 9 N.m (80 lb in).

  2. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953489), or equivalent to the threads of the exhaust manifold bolts.
  3. Position the exhaust manifold and a NEW gasket into place.
  4. Install the exhaust manifold bolts.

    Tighten: 

    1. Tighten the exhaust manifold bolts a first pass to 15 N.m (11 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, working toward the outside bolts.
    2. Tighten the exhaust manifold bolts a final pass to 25 N.m (18 lb ft). Tighten the exhaust manifold bolts beginning with the center two bolts. Alternate from side-to-side, working toward the outside bolts.

  5. Bend over the exposed edge of the exhaust manifold gasket at the rear of the cylinder head.
    6. Fig 2: Left Ignition Coil Bracket & Studs
    GM697215Courtesy of GENERAL MOTORS CORP.
  6. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 5.7 L.
  7. Place the ignition coil bracket into place.
  8. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the coil bracket studs.
  9. Install the ignition coil bracket studs.

    Tighten:  Tighten the ignition coil bracket studs to 12 N.m (106 lb in).

    10. Fig 3: Identifying Vacuum Booster Hose
    GM63936Courtesy of GENERAL MOTORS CORP.
  10. Install the brake booster vacuum hose to the brake booster.
    11. Fig 4: AIR Pipe, Gasket & Bolts
    GM651876Courtesy of GENERAL MOTORS CORP.
  11. Install the AIR pipe (with check valve) and a NEW gasket.
  12. Install the AIR pipe bolts.

    Tighten:  Tighten the AIR pipe bolts to 20 N.m (15 lb ft).

    13. Fig 5: Right/Left Check Valve, AIR Injection Pipe Hose & AIR Pipe
    GM651875Courtesy of GENERAL MOTORS CORP.
  13. Install the AIR pipe (2).
  14. Install the AIR injection pipe hose (3) to the left check valve.
  15. Install the AIR injection pipe hose (1) to the right check valve.
  16. Install the hose clamps at the right and left check valves.
    17. Fig 6: AIR Pipe Hose & Hose Clamp
    GM651891Courtesy of GENERAL MOTORS CORP.
  17. Install the AIR hose to the AIR pipe.
  18. Install the hose clamp at the AIR pipe.
  19. Raise the vehicle.
    20. Fig 7: Oxygen Sensor Electrical Connector
    GM53269Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Oxygen Sensor Notice in Cautions and Notices.
  20. Apply anti-sieze compound GM P/N 12377953 or equivalent to the threads of the oxygen sensor.
  21. Install the oxygen sensor.

    Tighten:  Tighten the oxygen sensor to 42 N.m (30 lb ft).

  22. Install the oxygen sensor connector clip at the body.
  23. Connect the oxygen sensor electrical connector.
  24. Install the CPA lock.
    25. Fig 8: Exhaust Manifold & Nuts
    GM676192Courtesy of GENERAL MOTORS CORP.
  25. Install the exhaust manifold nuts.

    Tighten:  Tighten the exhaust manifold nuts to 20 N.m (15 lb ft).

  26. Lower the vehicle.
  27. Install the generator. Refer to Generator Replacement in Engine Electrical.
    28. Fig 9: Generator Fuel Rail Cover
    GM651873Courtesy of GENERAL MOTORS CORP.
  28. Install the fuel rail cover.
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