Exhaust Manifold Replacement 2.2L (L61)

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.



2. Remove the exhaust manifold heat shield.



3. Remove the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls-2.2L (L61).
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.




Notice: Do not bend the exhaust flex decoupler more than 3 degrees in any direction. Movement of more than 3 degrees will damage the exhaust flex decoupler.

5. Remove the pipe to manifold nuts (3).
6. Pull down and back on the exhaust pipe in order to disengage the pipe from the exhaust manifold.
7. Lower the vehicle.



8. Remove the exhaust manifold to cylinder head nuts.
9. Remove the exhaust manifold.
10. Clean all the sealing surfaces.

1. Install a new exhaust manifold gasket.
2. Install the exhaust manifold to the cylinder head.




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.

Important: Install the new exhaust nuts.

3. Install the new exhaust manifold to cylinder head retaining nuts. Follow the tightening sequence.

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

4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



5. Install a new exhaust manifold to flex coupler gasket (2).
6. Push the flex coupler into position on the exhaust manifold.

Important: Install the new exhaust nuts.

7. Install the retaining nuts (3) which secure the manifold to the flex decoupler (4).

Tighten
Tighten the nuts to 30 N·m (22 lb ft).

8. Lower the vehicle.



9. Install the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls-2.2L (L61).



10. Install the exhaust manifold heat shield.

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

11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.