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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1771 (Engine Exhaust) >> Repair Instructions >> Exhaust Manifold Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Manifold Gasket
    GM949143Courtesy of GENERAL MOTORS CORP.
  1. Install a new manifold gasket on the cylinder head.
    2. Fig 2: View Of Exhaust Manifold & Gasket
    GM746061Courtesy of GENERAL MOTORS CORP.
  2. Install the exhaust manifold.
    3. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the exhaust manifold nuts.

    Tighten:  Tighten the exhaust manifold-to-cylinder head nuts L61 to 18 N.m (13 lb ft).

  4. If necessary, transfer the O2 sensor from the old manifold.
    5. IMPORTANT: Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound such as Permatex® 77124, SA P/N 21485279 or equivalent.
  5. Install the O2 sensor into the exhaust manifold.

    Tighten:  Tighten the O2 sensor to 45 N.m (33 lb ft).

    6. Fig 3: Gasket & Exhaust Pipe
    GM926819Courtesy of GENERAL MOTORS CORP.
  6. Install the gasket and exhaust pipe to the intermediate pipe.
  7. Install the exhaust pipe-to-intermediate pipe nuts.

    Tighten:  Tighten the exhaust pipe-to-intermediate pipe nuts L61 to 30 N.m (22 lb ft).

  8. Attach the rear O2 sensor wire to the heat shield.
    9. Fig 4: Exhaust Manifold Gasket
    GM898154Courtesy of GENERAL MOTORS CORP.
  9. Install a new exhaust manifold gasket onto the exhaust manifold flange studs.
  10. Position the exhaust manifold pipe onto the exhaust manifold studs and install the exhaust manifold nuts.

    Tighten:  Tighten the exhaust manifold pipe-to-exhaust manifold nuts L61 to 42 N.m (31 lb ft).

    11. Fig 5: Exhaust Manifold Heat Shield (2.2L)
    GM951395Courtesy of GENERAL MOTORS CORP.
  11. Lower the vehicle.
  12. Install the exhaust manifold heat shield.
  13. Install the exhaust manifold heat shield bolts.

    Tighten:  Tighten the exhaust manifold heat shield bolts L61 to 23 N.m (17 lb ft).

    14. Fig 6: Identifying Outlet Resonator/Duct Assembly
    GM898897Courtesy of GENERAL MOTORS CORP.
  14. Install the outlet resonator/duct assembly into position.
  15. Connect the PVC fresh air vent hose assembly.
  16. Tighten the clamp at the throttle body assembly.
  17. Position the outlet resonator/duct assembly up with the support bracket and install the push-pin.
  18. Tighten the air cleaner assembly.
  19. Connect the intake air temperature (IAT) sensor connector.
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