Chevrolet Blazer/Jimmy 1969-1982 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



6 Cylinder Engines
1969-74 MODELS

Refer to the "Intake Manifold Removal and Installation" procedure in this section.

1975-77 MODELS
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the power steering pump and, if equipped, the AIR pump.
  6.  
  7. Remove the Early Fuel Evaporation (EFE) valve bracket.
  8.  
  9. Disconnect the throttle controls and the throttle return spring.
  10.  
  11. Disconnect the exhaust pipe at the manifold flange.
  12.  
  13. Remove the manifold attaching bolts and remove the manifold. Discard the gasket.
  14.  

To install:

  1. Check for cracks in the manifold before it is replaced.
  2.  
  3. Install a new gasket on the exhaust manifold.
  4.  
  5. Clean and oil the bolts and install the bolts, torquing them to specifications.
  6.  
  7. Connect the exhaust pipe, throttle controls, and return spring. Install the air cleaner, start the engine, and check for leaks.
  8.  

1975-82 MODELS


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Fig. Fig. 1 Exhaust manifold bolt tightening sequence-1975-82 models with integral intake manifold/cylinder head

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the power steering pump and/or the AIR pump brackets, if so equipped.
  6.  
  7. Raise the truck and disconnect the exhaust pipe at the manifold. Disconnect the converter bracket at the transmission mount. If the vehicle is equipped with a manifold converter, disconnect the exhaust pipe from the converter and remove the converter.
  8.  
  9. Lower the truck and remove the rear heat shield and the accelerator cable bracket.
  10.  
  11. Remove the exhaust manifold bolts and remove the manifold.
  12.  
  13. Refer to steps 8-11 of the 1975-77 procedure.
  14.  

V8


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Fig. Fig. 2 Exploded view of the carburetor heat stove assembly-1977-82 models



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Fig. Fig. 3 To remove the exhaust manifold assembly, loosen the spark plug heat shield-to-exhaust manifold bolts ...



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Fig. Fig. 4 ... then remove the heat shield from the vehicle



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Fig. Fig. 5 Unfasten the exhaust pipe-to-manifold bolts and hang the pipe out of the way



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Fig. Fig. 6 Remove the exhaust manifold bolts ...



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Fig. Fig. 7 ... then remove the manifold assembly



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Fig. Fig. 8 Remove the old exhaust manifold gasket and clean both mating surfaces

  1. If equipped with AIR, remove the air injector assembly. The 1 / 4 inch pipe threads in the manifold are straight cut threads. Do not use a 1 / 4 inch tapered pipe tap to clean the threads.
  2.  
  3. Disconnect the battery.
  4.  
  5. If equipped, remove the carburetor air heater assembly.
  6.  
  7. Remove the spark plug wire heat shields.
  8.  
  9. On the left exhaust manifold, disconnect and remove the alternator.
  10.  
  11. Disconnect the exhaust pipe from the manifold and hang it from the frame out of the way.
  12.  
  13. Bend the locktabs and remove the end bolts, then the center bolts. Remove the manifold.
  14.  

A 9 / 16 inch thin wall 6-point socket, sharpened at the leading edge and tapped onto the head of the bolt, simplifies bending the locktabs.

To install:

  1. Installation is the reverse of removal. Clean all mating surfaces and use new gaskets. When installing a new right side manifold on 1977 and later models, the carburetor heat stove assembly must be transferred from the old unit. See the illustration. Torque all bolts to specifications from the inside working out.
  2.  

Diesel Engine
RIGHT SIDE
  1. Disconnect the batteries.
  2.  
  3. Raise the truck and disconnect the exhaust pipe from the manifold. Lower the truck.
  4.  
  5. Tag and disconnect the glow plug wires. Remove the air cleaner duct bracket.
  6.  
  7. Remove the glow plugs, unscrew the manifold bolts and remove the manifold.
  8.  
  9. Installation is in the reverse order.
  10.  

LEFT SIDE
  1. Disconnect the batteries.
  2.  
  3. Remove the dipstick tube nut. Remove the dipstick tube.
  4.  
  5. Tag and disconnect the glow plug wires and remove the glow plugs.
  6.  
  7. Remove the manifold bolts. Raise the car and disconnect the exhaust pipe at the manifold.
  8.  
  9. Remove the manifold from the bottom.
  10.  
  11. Start the manifold bolts while the car is still raised, lower the truck and then install the remaining components in the reverse order.
  12.  

 
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