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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 - Right >> 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 clean and free of debris or threadlocking material.

    Fig 1: Right Exhaust Manifold, Bolts & Gasket
    GM639833Courtesy 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 10953488) 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 front of the right cylinder head.
    6. Fig 2: Right Ignition Coil Bracket & Studs
    GM697216Courtesy of GENERAL MOTORS CORP.
  6. Install the ignition coil bracket.
  7. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the bracket studs.
  8. Install the ignition coil bracket studs.

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

  9. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 5.7 L.
  10. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical - 5.7 L.
    11. Fig 3: Right AIR Pipe Gasket, Bolt & Oil Level Indicator Tube
    GM651877Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the AIR pipe bracket slides behind the bolt at the left cylinder head.
  11. Position the AIR pipe (with check valve) and NEW gasket into place.
  12. Install the AIR pipe bolts.

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

    13. Fig 4: Rear Left Cylinder Head, AIR Pipe & Bolt
    GM651878Courtesy of GENERAL MOTORS CORP.
  13. Tighten the AIR pipe bolt at the rear of the left cylinder head.

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

    14. Fig 5: Right/Left Check Valve, AIR Injection Pipe Hose & AIR Pipe
    GM651875Courtesy of GENERAL MOTORS CORP.
  14. Install the AIR pipe hose (1) to the right check valve.
  15. Install the hose clamp at the right check valve.
  16. Raise the vehicle.
    17. Fig 6: Oxygen Sensor Electrical Connector & CPA Lock
    GM676532Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Oxygen Sensor Notice in Cautions and Notices.
  17. Apply anti-sieze compound GM P/N 12377953 or equivalent to the threads of the oxygen sensor.
  18. Install the oxygen sensor.

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

  19. Connect the oxygen sensor electrical connector.
  20. Install the CPA lock.
    21. Fig 7: Exhaust Manifold & Nuts
    GM676192Courtesy of GENERAL MOTORS CORP.
  21. Install the exhaust manifold nuts. (left side shown, right side similar)

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

  22. Lower the vehicle.
    23. Fig 8: Fuel Rail Cover
    GM651872Courtesy of GENERAL MOTORS CORP.
  23. Install the fuel rail cover.
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