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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 602 (Engine Exhaust System) >> Repair Instructions >> Exhaust Manifold Replacement - Right (3.8L) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Buick Regal and 2002 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the exhaust manifold studs if removed.
    Fig 1: Exhaust Manifold Studs
    G01766072Courtesy of GENERAL MOTORS CORP.
  2. Install the heated oxygen sensor to the right exhaust manifold. Refer to HEATED OXYGEN SENSOR
  3. Install the lower exhaust manifold heat shield.
    Fig 2: Lower Exhaust Manifold Heat Shield
    G01766073Courtesy of GENERAL MOTORS CORP.
  4. Install the upper exhaust manifold heat shield.
    Fig 3: Upper Exhaust Manifold Heat Shield
    G01766074Courtesy of GENERAL MOTORS CORP.
  5. Install the new exhaust manifold gasket.
  6. Install the exhaust manifold.
  7. Install the exhaust manifold bolt behind the oxygen sensor.
  8. Connect the heated oxygen sensor electrical connector.
  9. Return the engine to the original position.
  10. Install the remaining exhaust manifold bolts and nuts.

    Tighten 

    Tighten the bolts and the nuts to 30 N.m (22 lb ft).

    Fig 4: Exhaust Manifold And Components
    G01766075Courtesy of GENERAL MOTORS CORP.
  11. Install the fuel injector sight shield bracket.
  12. Install the fuel injector sight shield bracket nuts.

    Tighten 

    Tighten the nuts to 30 N.m (22 lb ft).

    Fig 5: Fuel Injector Sight Shield Bracket
    G01766076Courtesy of GENERAL MOTORS CORP.
  13. Install the engine lift bracket.
  14. Install the engine lift bracket bolt and the nut.

    Tighten 

    Tighten the bolt and the nut to 30 N.m (22 lb ft).

    Fig 6: Engine Lift Bracket
    G01766077Courtesy of GENERAL MOTORS CORP.
  15. Install the right spark plug wires.
  16. Install the wiring harness and the heater hose retaining clips to the fuel injector sight shield bracket.
  17. Raise the vehicle.

    Important:  Whenever the EGR pipe is removed from the right exhaust manifold, the outlet pipe should be inspected for leaks during installation. If leaks are present, replace the EGR adapter.

  18. Install the EGR pipe to the right exhaust manifold.
  19. Install the EGR pipe bolt.

    Tighten 

    Tighten the bolt to 29 N.m (21 lb ft).

    Fig 7: EGR Pipe And Bolt
    G01766078Courtesy of GENERAL MOTORS CORP.
  20. Install the 3-way catalytic converter to the right exhaust manifold. Refer to Catalytic Converter Replacement (3.1 L)  or Catalytic Converter Replacement (3.8L)  .
  21. Lower the vehicle.
  22. Install the exhaust crossover pipe to the right exhaust manifold. Refer to Exhaust Crossover Pipe Replacement (3.1 L)  or Exhaust Crossover Pipe Replacement (3.8L) 
    23. Fig 8: Exhaust Crossover Pipe Heat Shield
    G01766079Courtesy of GENERAL MOTORS CORP.
  23. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36) or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67)
  24. Connect the negative battery cable.
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