GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1999 🢒 Sunfire 🢒 Engine 🢒 Engine Mechanical - 2.2L 🢒 Exhaust Manifold Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Partially drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

    3. Object Number: 3295 Size: SH
  3. Remove the oxygen sensor lead.
  4. Remove the drive belt. Refer to Drive Belt Replacement
  5. Remove the generator rear brace.
  6. Remove the generator. Refer to Generator Replacement in Engine Electrical.
  7. Remove the radiator inlet pipe.

    8. Object Number: 182862 Size: SH
  8. Raise and support the vehicle. Refer to General Vehicle Lifting and Jacking in General Information.
  9. Remove the exhaust pipe to the exhaust manifold.
  10. Lower the vehicle.
  11. Remove the oil fill tube. Refer to Oil Level Indicator and Tube Replacement
  12. Remove the heater outlet hose assembly nut from the exhaust manifold.

    13. Object Number: 182885 Size: SH
  13. Remove the exhaust manifold nuts.
  14. Remove the exhaust manifold and the gasket.
  15. Clean the mating surfaces at the cylinder head and the exhaust manifold.
  16. Inspect the manifold for cracks, broken flanges and gasket surface damage.
  17. Check the alignment of the exhaust manifold mating surfaces. Use a straight edge and a feeler gauge. If the flanges or the mating surfaces do not align, the manifold is warped and should be replaced.

Installation Procedure

    Object Number: 182885 Size: SH
  1. Install the exhaust manifold gasket.
  2. Install the exhaust manifold.

    3. Notice: 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.

  3. Install the exhaust manifold nuts.

    4. Tighten
    Tighten the nuts to 13 N·m (115 lb in).

  4. Install the heater outlet hose assembly nut.

    5. Tighten
    Tighten the nut to 25 N·m (18 lb ft).

  5. Install the oil fill tube. Refer to Oil Level Indicator and Tube Replacement
  6. Raise the vehicle. Refer to General Vehicle Lifting and Jacking in General Information.
  7. Install the exhaust pipe to the manifold. Refer to Intermediate Pipe Replacement in Engine Exhaust.
  8. Lower the vehicle.
  9. Install the radiator inlet pipe.

    10. Object Number: 182862 Size: SH
  10. Install the generator. Refer to Generator Replacement in Engine Electrical.
  11. Install the generator rear brace.
  12. Install the drive belt. Refer to Drive Belt Replacement
  13. Install the oxygen sensor lead.

    14. Object Number: 3295 Size: SH
  14. Connect the negative battery cable.

    15. Tighten
    Tighten the bolt to 16 N·m (12 lb ft).

  15. Refill the cooling system, Refer to Cooling System Draining and Filling in Engine Cooling.