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HOMESERVICE MANUALSGMC1999FORWARD CONTROL 5.7 R, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 687 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST MANIFOLD REPLACEMENT - RIGHT (3.1 L)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 2003 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. If replacing the right exhaust manifold install the heated oxygen (HO2S) sensor. Refer to HEATED OXYGEN SENSOR in Engine Controls - 3.1 L.
    Fig 1: Installing Heated Oxygen Sensor
    G02080666Courtesy of GENERAL MOTORS CORP.
  2. Install the right exhaust manifold gasket.
  3. Install the right exhaust manifold.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Install the right exhaust manifold nuts.

    Tighten 

    Tighten the nuts to 16 N.m (12 lb ft).

    Fig 2: Installing Gasket And Right Exhaust Manifold
    G02080667Courtesy of GENERAL MOTORS CORP.
  5. Install the right exhaust manifold lower heat shield.
  6. Install the right exhaust manifold lower heat shield bolts.

    Tighten 

    Tighten the bolts to 10 N.m (89 lb in).

    Fig 3: Installing Right Exhaust Manifold Lower Heat Shield And Bolts
    G02080668Courtesy of GENERAL MOTORS CORP.
  7. Install the right exhaust manifold upper heat shield.
  8. Install the right exhaust manifold upper heat shield bolts.

    Tighten 

    Tighten the bolts to 10 N.m (89 lb in).

  9. Install the EGR pipe to the right exhaust manifold. Refer to EGR VALVE PIPE in Engine Controls-3.1 L.
  10. Install the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT (3.1L)  or CATALYTIC CONVERTER REPLACEMENT (3.8L)  .
  11. Lower the vehicle.
    Fig 4: Installing Right Exhaust Manifold Upper Heat Shield And Bolts
    G02080669Courtesy of GENERAL MOTORS CORP.
  12. Install the exhaust crossover pipe nuts to the right exhaust manifold.

    Tighten 

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

    Fig 5: Installing Exhaust Crossover Pipe Nuts To Right Exhaust Manifold
    G02080670Courtesy of GENERAL MOTORS CORP.
  13. Install the exhaust crossover pipe heat shield.
  14. Install the exhaust crossover pipe heat shield bolts.

    Tighten 

    Tighten the bolts to 10 N.m (89 lb in).

  15. Install the thermostat bypass pipe. Refer to THERMOSTAT BYPASS PIPES REPLACEMENT in Engine Cooling.
    Fig 6: Installing Exhaust Crossover Pipe Heat Shield And Bolts
    G02080671Courtesy of GENERAL MOTORS CORP.
  16. Connect the heated oxygen (HO2S) sensor electrical connector.
  17. Install the ignition control module and the ignition control module bracket. Refer to IGNITION CONTROL MODULE in Engine Controls-3.1 L.
  18. Install the MAP sensor. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR in Engine Controls - 3.1L.
  19. Return the engine to the original position.
  20. Install the engine mount struts. Refer to ENGINE MOUNT STRUT REPLACEMENT in Engine Mechanical - 3.1 L.
  21. Install the accelerator and cruise control cables with the bracket to the throttle body.
  22. Install the air cleaner intake duct.
  23. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
    Fig 7: Connecting Heated Oxygen Sensor Electrical Connector
    G02080672Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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When to See a Mechanic

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.