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Home >> GMC >> 2002 >> Jimmy 2D Utility, Part Time, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Exhaust Manifold Replacement >> Installation Procedure
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Installation Procedure

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.
  1. Install the heat shield and bolts to the exhaust manifold, if removed.

    Tighten 

    Tighten the heat shield bolts to 12 N.m (106 lb in).

    2. Fig 1: Exhaust Manifold Heat Shield Bolts
    G01660142Courtesy of GENERAL MOTORS CORP.
  2. Install the exhaust manifold gasket and exhaust manifold.
  3. Install the exhaust manifold nuts.

    Tighten 

    Tighten the exhaust manifold nuts to 13 N.m (115 lb in).

    4. Fig 2: Exhaust Manifold Nuts
    G01660143Courtesy of GENERAL MOTORS CORP.
  4. Install the air injection pipe with gasket.

    Tighten 

    • Tighten the air injection pipe nut (1) to 13 N.m (115 lb in).
    • Tighten the air injection pipe nut (2) to 10 N.m (89 lb in).
    5. Fig 3: Air Injection Pipe Nuts
    G01660144Courtesy of GENERAL MOTORS CORP.
  5. Install the oxygen sensor, if removed. Refer to OXYGEN SENSORS .
  6. Install the oil level indicator tube. Refer to OIL LEVEL INDICATOR AND TUBE REPLACEMENT .
  7. Install the power steering pump.
    Fig 4: Power Steering Pump Bolts And Studs
    G01660145Courtesy of GENERAL MOTORS CORP.
    1. 7.1. Loosely install the power steering pump to accessory mounting bracket 3 bolts.
    2. 7.2. Loosely install the 2 nuts holding the power steering pump bracket to the cylinder head studs.
    3. 7.3. Loosely install the power steering pump lower bracket bolt.
  8. Tighten the fasteners in the following sequence:

    Tighten 

    1. 8.1. Tighten the accessory mounting bracket 3 bolts to 30 N.m (22 lb ft).
    2. 8.2. Tighten the cylinder head stud 2 nuts to 50 N.m (37 lb ft).
    3. 8.3. Tighten the lower bracket bolt to 50 N.m (37 lb ft).
  9. Install the air conditioning compressor, if equipped. Refer to COMPRESSOR in Heating, Ventilation and Air Conditioning.
  10. Raise the vehicle. Refer to LIFTING & JACKING THE VEHICLE in General Information.
  11. Install the exhaust pipe to the exhaust manifold. Refer to Exhaust Manifold Pipe Replacement .
  12. Install the drive belt. Refer to Drive Belt Replacement .
  13. Lower the vehicle.
  14. Install the upper fan shroud. Refer to FAN SHROUD REPLACEMENT in Engine Cooling.
  15. Connect the battery negative cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
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