GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2003 🢒 Grand Am 🢒 Engine 🢒 Engine Exhaust 🢒 Exhaust Manifold Replacement

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

    2. Object Number: 746055 Size: SH
  2. Remove the exhaust manifold heat shield.

    3. Object Number: 412121 Size: SH
  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.

    5. Object Number: 783174 Size: SH

    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. Object Number: 746061 Size: SH
  8. Remove the exhaust manifold to cylinder head nuts.
  9. Remove the exhaust manifold.
  10. Clean all the sealing surfaces.

Installation Procedure

    Object Number: 746061 Size: SH
  1. Install a new exhaust manifold gasket.
  2. Install the exhaust manifold to the cylinder head.

    3. Object Number: 60046 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.

    Important: Install the new exhaust nuts.

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

    4. Tighten
    Tighten the nuts to 12 N·m (9 lb ft).

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

    5. Object Number: 783174 Size: SH
  5. Install a new exhaust manifold to flex coupler gasket (2).
  6. Push the flex coupler into position on the exhaust manifold.

    7. Important: Install the new exhaust nuts.

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

    8. Tighten
    Tighten the nuts to 45 N·m (33 lb ft).

  8. Lower the vehicle.

    9. Object Number: 412121 Size: SH
  9. Install the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls-2.2L (L61).

    10. Object Number: 746055 Size: SH
  10. Install the exhaust manifold heat shield.

    11. 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.