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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 809 (Engine Exhaust System) >> Repair Instructions >> Exhaust Manifold Replacement - Right (8.1L Engine) >> Installation Procedure

Installation Procedure

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  1. Install a NEW exhaust manifold gasket.
  2. Install the exhaust manifold.
    3. Fig 1: Installing Exhaust Manifold
    G02119409Courtesy of GENERAL MOTORS CORP.
  3. Install the exhaust manifold bolt and nuts.
    NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    Tighten 

    • Tighten the bolt to 35 N.m (26 lb ft).
    • Tighten the nuts to 16 N.m (12 lb ft).
  4. Raise the vehicle.
  5. Install the exhaust manifold heat shield.
    6. Fig 2: Installing Exhaust Manifold Heat Shield
    G02119410Courtesy of GENERAL MOTORS CORP.
  6. Install the exhaust manifold heat shield bolts and nuts.

    Tighten 

    Tighten the bolts and nuts to 25 N.m (18 lb ft).

  7. Lower the vehicle.
  8. Position the EGR (2).
    9. Fig 3: Installing Exhaust Gas Recirculation (EGR) Pipe, Bolt And Nuts
    G02119411Courtesy of GENERAL MOTORS CORP.
  9. Install a NEW EGR pipe gasket.
  10. Install the EGR pipe bracket bolt (4).

    Tighten 

    Tighten the bolt to 50 N.m (37 lb ft).

  11. Install the EGR pipe nuts (5) to the exhaust manifold.

    Tighten 

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

  12. Install the spark plugs. Refer to SPARK PLUGS in Engine Controls - 8.1L
  13. Coat the threads of the sensor with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent.
  14. Install the ECT sensor.

    Tighten 

    Tighten the sensor to 20 N.m (15 lb ft).

    Fig 4: Installing ECT Sensor
    G02119412Courtesy of GENERAL MOTORS CORP.

    Important:  Fully install the spark plug wires by pushing on the exposed end of the spark plug boot. Do not push the spark plug wire on to the spark plug by using the metal heat shield.

  15. Install the spark plug wires to the spark plugs and ignition coils.
    16. Fig 5: Installing Spark Plug Wires To Spark Plugs And Ignition Coils
    G02119413Courtesy of GENERAL MOTORS CORP.
  16. Install the oil level indicator tube.
  17. Install the wheelhouse panel. Refer to WHEELHOUSE PANEL REPLACEMENT in Body Front End.
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