Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sonoma, 2003 GMC Jimmy, 2003 Chevrolet S10 Pickup, and 2003 Chevrolet Blazer. However, it is still accessible from the selected car via links, so may be relevant.

Important: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and bolts in place.

Sub-assemble the bolts, spark plug wire shields, and NEW gaskets to the exhaust manifold.
The stud installs in the front hole.
Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
From under the hood position the exhaust manifold by the engine.
Raise the vehicle to the proper height.

Fig 1: Identifying New Exhaust Manifold Gasket
Courtesy of GENERAL MOTORS CORP.
Working the wheelhouse opening, install the exhaust manifold.
Install the spark plug wire shields.
If reusing the fasteners, apply threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the threads of the exhaust manifold bolts and stud.
NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
Install the exhaust manifold bolts and stud.
Tighten
1. 8.1. Tighten the exhaust manifold bolts and stud on the first pass to 15 N.m (11 lb ft).
2. 8.2. Tighten the exhaust manifold bolts and stud on the final pass to 30 N.m (22 lb ft).
Install the spark plug wires to the spark plug wire retainers.
Install the spark plug wires onto the spark plugs.

Fig 2: Installing Exhaust Manifold
Courtesy of GENERAL MOTORS CORP.
Install the fender wheelhouse extension.
Install the front tire to. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
Raise the vehicle. Refer to JACKING AND LIFTING in General Information.
Connect the exhaust pipe to the exhaust manifold. Refer to Exhaust Manifold Pipe Replacement .
Lower the vehicle.

Fig 3: Installing Fender Wheelhouse Extension
Courtesy of GENERAL MOTORS CORP.
Connect the ECT sensor electrical connector.

Fig 4: Connecting ECT Sensor Electrical Connector
Courtesy of GENERAL MOTORS CORP.
Install the radiator inlet hose support bracket and nut.
Tighten

Tighten the radiator inlet hose support bracket nut to 36 N.m (27 lb ft).
Install the intermediate steering shaft. Refer to INTERMEDIATE STEERING SHAFT REPLACEMENT - LOW in Steering Wheel and Column.

Fig 5: Installing Radiator Inlet Hose Support Bracket And Nut
Courtesy of GENERAL MOTORS CORP.
NOTE:
- Handle the MAF sensor carefully.
- Do not drop the MAF sensor in order to prevent damage to the MAF sensor.
- Do not damage the screen located on the air inlet end of the MAF.
- Do not touch the sensing elements.
- Do not allow solvents and lubricants to come in contact with the sensing elements.
- Use a small amount of a soap based solution in order to aid in the installation.
Install air cleaner outlet duct to throttle body.
Install air cleaner outlet duct to MAF sensor.

Fig 6: Installing Air Cleaner Outlet Duct To Throttle Body
Courtesy of GENERAL MOTORS CORP.
Connect the IAT sensor harness connector.

Fig 7: Connecting IAT Sensor Harness Connector
Courtesy of GENERAL MOTORS CORP.
Install the air cleaner outlet duct retaining wingnut.

Fig 8: Installing Air Cleaner Outlet Duct Retaining Wingnut
Courtesy of GENERAL MOTORS CORP.
Connect the breather tube to the air cleaner outlet duct.

Fig 9: Connecting Breather Tube To Air Cleaner Outlet Duct
Courtesy of GENERAL MOTORS CORP.