GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2002 🢒 Sonoma Pickup - 4WD 🢒 Engine 🢒 Engine Exhaust 🢒 Exhaust Manifold Replacement

Removal Procedure
  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the drive belt. Refer to Drive Belt Replacement .
  4. Remove the exhaust pipe from the exhaust manifold. Refer to Exhaust Manifold Pipe Replacement .
  5. Lower the vehicle.
  6. Remove the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.

    7. Important: Do not evacuate the air conditioning system.

  7. Remove the air conditioning compressor, if equipped, and set it aside. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation and Air Conditioning.

    8. Object Number: 199010 Size: SH
  8. Remove the power steering pump and set it aside, using the following procedure:
    9. 8.1. Two nuts from the cylinder head studs
    8.2. One bolt from the rear bracket
    8.3. Three bolts from the front of the power steering pump

    The bolts are accessible through the holes in the power steering pump pulley.

  9. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .

    10. Object Number: 563829 Size: SH
  10. Disconnect the oxygen sensor electrical connection.

    11. Object Number: 601942 Size: SH
  11. Remove the oxygen sensor from the exhaust manifold to prevent damage to the sensor.

    12. Object Number: 601943 Size: SH
  12. Remove the air injection nuts (1, 2).
  13. Remove the air injection pipe from the exhaust manifold.

    14. Object Number: 601946 Size: SH
  14. Remove the exhaust manifold nuts.
  15. Remove the exhaust manifold.
  16. Remove the exhaust manifold gasket.

    17. Object Number: 563820 Size: SH
  17. Remove the heat shield, if replacing the exhaust manifold.
  18. Clean all sealing surfaces. Refer to Exhaust Manifold Cleaning and Inspection in Engine Mechanical - 2.2L Unit Repair.

Installation Procedure

    Object Number: 563820 Size: SH

    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.

  1. Install the heat shield and bolts to the exhaust manifold, if removed.

    2. Tighten
    Tighten the heat shield bolts to 12 N·m (106 lb in).


    Object Number: 601946 Size: SH
  2. Install the exhaust manifold gasket and exhaust manifold.
  3. Install the exhaust manifold nuts.

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


    Object Number: 601943 Size: SH
  4. Install the air injection pipe with gasket.

    5. Tighten

        • Tighten the air injection pipe nut (1) to 13 N·m (115 lb in).
        • Tighten the air injection pipe nut (2) to 10 N·m (89 lb in).
  5. Install the oxygen sensor, if removed. Refer to Oxygen Sensor Replacement in Engine Controls 2.2L (L43).
  6. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .

    7. Object Number: 199010 Size: SH
  7. Install the power steering pump.
    8. 7.1. Loosely install the power steering pump to accessory mounting bracket 3 bolts.
    7.2. Loosely install the 2 nuts holding the power steering pump bracket to the cylinder head studs.
    7.3. Loosely install the power steering pump lower bracket bolt.
  8. Tighten the fasteners in the following sequence:

    9. Tighten

    1. Tighten the accessory mounting bracket 3 bolts to 30 N·m (22 lb ft).
    2. Tighten the cylinder head stud 2 nuts to 50 N·m (37 lb ft).
    3. Tighten the lower bracket bolt to 50 N·m (37 lb ft).
  9. Install the air conditioning compressor, if equipped. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation and Air Conditioning.
  10. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  11. Install the exhaust pipe to the exhaust manifold. Refer to Exhaust Manifold Pipe Replacement .
  12. Install the drive belt. Refer to Drive Belt Replacement .
  13. Lower the vehicle.
  14. Install the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
  15. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.