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HOMESERVICE MANUALSGMC1999FORWARD CONTROL 5.7 R, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 402 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST MANIFOLD REPLACEMENT - RIGHT (LX5)INSTALLATION PROCEDURE
1999 GMC Forward Control 5.7 R, Automatic

Installation Procedure

1999 GMC Forward Control 5.7 R, AutomaticSECTION Installation Procedure
WARNING: This page is about a different car, the 2002 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.
  1. Place a NEW exhaust manifold crossover seal over the left exhaust manifold.
  2. Install the right exhaust manifold to the engine in the following order:
    1. 2.1. Align the exhaust manifold to the cylinder head.
    2. 2.2. Place the crossover portion of the exhaust manifold around the left exhaust manifold.
    3. 2.3. Hold the right exhaust manifold to the right cylinder head using a retaining bolt.
  3. Raise and support the vehicle.
  4. Grasp the right exhaust manifold and remove the retaining bolt.
  5. Place a NEW exhaust manifold gasket between the right exhaust manifold and the right cylinder head.
    CAUTION: Refer to FASTENER NOTICE .
  6. Install the right exhaust manifold bolts.

    Tighten 

    Tighten the exhaust manifold bolts to 25 N.m (18 ft lbs).

    7. Fig 1: Installing Right Exhaust Manifold & Gasket
    G01818186Courtesy of GENERAL MOTORS CORP.
  7. Connect the EGR inlet pipe to the right exhaust manifold.

    Tighten 

    Tighten the EGR inlet pipe nut to 60 N.m (44 ft lbs).

  8. Install the right exhaust manifold studs.

    Tighten 

    Tighten the exhaust manifold studs to 9 N.m (80 in lbs).

    9. Fig 2: Installing Right Exhaust Manifold Studs
    G01818187Courtesy of GENERAL MOTORS CORP.
  9. Install the heated oxygen sensor. Refer to UPSTREAM HEATED OXYGEN SENSOR .
  10. Install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement (LX5) .
  11. Install the two bolts attaching the left exhaust manifold to the right exhaust manifold crossover.

    Tighten 

    Tighten the exhaust manifold crossover bolts to 25 N.m (18 ft lbs).

    12. Fig 3: Installing Left Exhaust Manifold To Right Exhaust Manifold Crossover Bolts
    G01818188Courtesy of GENERAL MOTORS CORP.
  12. Lower the vehicle.
  13. Position the exhaust manifold heat shield to the left exhaust manifold.
  14. Install the bolts attaching the exhaust manifold heat shield to the left exhaust manifold.

    Tighten 

    Tighten the exhaust manifold heat shield bolts to 9 N.m (80 in lbs).

    Fig 4: Installing Exhaust Manifold Heat Shield
    G01818189Courtesy of GENERAL MOTORS CORP.
  15. Connect the harness (3) to the harness clip (1).
  16. Connect the C100 (2) to the transaxle.
    Fig 5: Connecting C 100 Harness Connector
    G01818190Courtesy of GENERAL MOTORS CORP.
  17. Connect the left wheel speed sensor connector (3) to the left wheel speed sensor.
  18. Attach the left wheel speed sensor lead (1) to the retaining brackets (2).
    Fig 6: Installing Left Wheel Speed Sensor
    G01818191Courtesy of GENERAL MOTORS CORP.
  19. Connect the C101 (2) at the left strut tower.
    Fig 7: Locating C 101
    G01818192Courtesy of GENERAL MOTORS CORP.
  20. Install the bolt (1) connecting the ground lead to the top of the transaxle.

    Tighten 

    Tighten the ground lead bolt to 17 N.m (13 ft lbs).

    Fig 8: Installing Ground Lead To Top Of Transaxle Bolt
    G01818193Courtesy of GENERAL MOTORS CORP.
  21. Insert the transaxle range selector cable into the bracket.
  22. Connect the transaxle range selector cable terminal to the transaxle manual shift lever pin.
    Fig 9: Installing Transaxle Range Selector Cable
    G01818194Courtesy of GENERAL MOTORS CORP.
  23. Install the retainer to the transaxle range selector cable mechanism.
    Fig 10: Installing Transaxle Range Selector Cable Mechanism Retainer
    G01818195Courtesy of GENERAL MOTORS CORP.
  24. Adjust the transaxle range selector cable. Refer to SHIFT CABLE .
  25. Install the transaxle filler tube. Refer to FLUID FILLER TUBE (4T65-E) .
  26. Install the vacuum brake booster. Refer to REMOVAL (L47) or REMOVAL (LX5) .
  27. Position the accelerator control cable bracket to the throttle body.
  28. Install the fasteners attaching the accelerator control cable bracket to the throttle body.

    Tighten 

    • Tighten the accelerator control cable bracket bolt to 13 N.m (115 in lbs).
    • Tighten the accelerator control cable bracket nuts to 10 N.m (89 in lbs).
  29. Install the air cleaner assembly.
  30. Install the air cleaner intake duct.
    Fig 11: Installing Accelerator Control Cable Bracket
    G01818196Courtesy of GENERAL MOTORS CORP.

    Important:  The throttle should operate freely without binding between full closed and wide open throttle.

  31. Connect the accelerator cable to the throttle body lever and bracket.
  32. Connect the cruise control cable (2) to the throttle body lever and bracket.
    Fig 12: Connecting Cruise Control Cable
    G01818197Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.