GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2009 🢒 Epica 🢒 Engine 🢒 Engine Exhaust 🢒 Exhaust Manifold Replacement

Removal Procedure

    Warning: Refer to Battery Disconnect Warning in the Preface section.


    Object Number: 1863838 Size: SH
  1. Disconnect the negative battery cable
  2. Remove the engine cover. Refer to Engine Cover Replacement
  3. Remove the charge air system hoses and ducts. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement

    4. Object Number: 1822512 Size: SH
  4. Remove the PCV valve and adapter. Refer to Positive Crankcase Ventilation Valve Replacement and Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.

    5. Object Number: 1820482 Size: SH
  5. Remove the exhaust heat shield.

    6. Object Number: 1820618 Size: SH
  6. Remove the pre-catalyst. Refer to Catalytic Converter Replacement
  7. Remove the turbocharger from the exhaust manifold. Refer to Turbocharger Replacement

    8. Object Number: 1822528 Size: SH
  8. Remove the EGR cooler inlet pipe from the EGR valve with the gasket.
  9. Remove the exhaust manifold with the EGR cooler inlet pipe.
  10. Remove the EGR cooler inlet pipe from the exhaust manifold.

Installation Procedure

    Object Number: 1822528 Size: SH
  1. Install the EGR cooler inlet pipe to the exhaust manifold.
  2. Install the exhaust manifold to the cylinder head with a new gasket.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the EGR cooler inlet pipe to the EGR valve with a new gasket.
    4. • Tighten the EGR cooler inlet pipe nuts (to exhaust manifold) to 33 N·m (24.3 lb ft).
    • Tighten the exhaust manifold nuts to 33 N·m (24.3 lb ft).
    • Tighten the EGR cooler inlet pipe bolts (to EGR valve) to 20 N·m (14.8 lb ft).

    Object Number: 1820482 Size: SH
  4. Install the exhaust manifold heat shield and tighten to 20 N·m (14.8 lb ft).