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For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2003 🢒 Vibe - AWD 🢒 Engine 🢒 Engine Exhaust 🢒 Exhaust Manifold Replacement

Exhaust Manifold Replacement 2WD

Removal Procedure

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

    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. Raise and properly support the vehicle. Refer to Lifting and Jacking the Vehicle .

    3. Object Number: 836332 Size: SH
  3. Remove the heated oxygen sensor (HO2S) 1 (1). Refer to Heated Oxygen Sensor 1 Replacement .
  4. Remove the exhaust pipe hanger (2).
  5. Remove the following components from the exhaust manifold flange:
    6. • Two bolts
    • The springs
  6. Remove the exhaust manifold flange gasket.

    7. Object Number: 234425 Size: SH
  7. Remove one bolt (1) from the manifold support bracket to exhaust manifold.

    8. Object Number: 836343 Size: SH
  8. Remove the upper heat insulator bolts.
  9. Remove the upper heat insulator.
  10. Remove the 2 exhaust manifold nuts (1) and 3 exhaust manifold bolts (2).
  11. Remove the following components:
    12. • The exhaust manifold
    • The exhaust manifold gasket
  12. Remove the lower heat insulator bolts.
  13. Remove the lower heat insulator.

Installation Procedure

    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 lower heat insulator.
  2. Install the lower heat insulator bolts.

    3. Tighten
    Tighten the lower heat insulator bolts to 12 N·m (9 lb ft).

  3. Install the following components:
    4. • The exhaust manifold gasket
    • The exhaust manifold
  4. Install the 2 exhaust manifold nuts (1) and 3 exhaust manifold bolts (2).

    5. Tighten
    Tighten the exhaust manifold nuts and bolts to 37 N·m (27 lb ft).

  5. Install the upper heat insulator.

    6. Object Number: 836343 Size: SH
  6. Install the upper heat insulator bolts.

    7. Tighten
    Tighten the upper heat insulator bolts to 18 N·m (13 lb ft).


    Object Number: 234425 Size: SH
  7. Install one bolt (1) to the manifold support bracket to exhaust manifold.

    8. Tighten
    Tighten the exhaust manifold support bracket bolt to 49 N·m (37 lb ft).

  8. Install the exhaust manifold flange gasket.
  9. Install the following components to the exhaust manifold flange:
    10. • The springs
    • Two bolts

    Tighten
    Tighten the exhaust manifold flange bolts to 43 N·m (32 lb ft).

  10. Install the exhaust pipe hanger (2).

    11. Object Number: 836332 Size: SH
  11. Install the HO2S1 (1). Refer to Heated Oxygen Sensor 1 Replacement .
  12. Lower the vehicle.

    13. 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.

  13. Connect the negative battery cable.

Exhaust Manifold Replacement 2WD

Removal Procedure

Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

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

    3. Object Number: 836734 Size: SH
  3. Disconnect the Heated Oxygen Sensor electrical connectors.
    4. • Disconnect the Heated Oxygen Sensor (HO2S1) electrical connector (1). Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 1.8L (LV6) or Heated Oxygen Sensor 1 Replacement Engine Controls - 1.8L (LNK).
    • Disconnect the Heated Oxygen Sensor (HO2S2) electrical connector (2). Refer to Heated Oxygen Sensor 2 Replacement in Engine Controls - 1.8L (LV6) or Heated Oxygen Sensor 2 Replacement Engine Controls - 1.8L (LNK).
  4. Remove the exhaust pipe hangers (3).
  5. Remove the following components from the exhaust manifold flange:
    6. • 2 bolts (4)
    • The springs (5)
  6. Remove the exhaust manifold flange gasket.

    7. Object Number: 824940 Size: SH
  7. Remove 1 bolt from the manifold support bracket to exhaust manifold.
  8. Remove the upper heat insulator bolts.
  9. Remove the upper heat insulator.

    10. Object Number: 828857 Size: SH
  10. On 1.8L LNK engine, remove the 3 exhaust manifold bolts (1-3) and 2 exhaust manifold nuts (4-5).

    11. Object Number: 234429 Size: SH
  11. On 1.8L LV6 engine, remove the exhaust manifold bolts (1-5).
  12. On all engines, remove the following components:
    13. • The exhaust manifold
    • The exhaust manifold gasket
  13. Remove the lower heat insulator bolts.
  14. Remove the lower heat insulator.

Installation Procedure

    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 lower heat insulator to the exhaust manifold.

    2. Tighten
    Tighten the lower heat insulator bolts to 18 N·m (13 lb ft).

  2. Install the following components:
    3. • The exhaust manifold gasket
    • The exhaust manifold

    Object Number: 234429 Size: SH
  3. On 1.8L LV6 engines, install the exhaust manifold bolts (1-5).

    4. Tighten
    Tighten the exhaust manifold to nuts and bolts to 50 N·m (37 lb ft).


    Object Number: 828857 Size: SH
  4. On 1.8L LNK engines, install the 3 exhaust manifold bolts (1-3) and 2 exhaust manifold nuts (4-5).

    5. Tighten
    Tighten the exhaust manifold to nuts and bolts to 50 N·m (37 lb ft).

  5. Install the upper heat insulator.
  6. Install the upper heat insulator bolts.

    7. Tighten
    Tighten the upper heat insulator bolts to 37 N·m (27 lb ft).


    Object Number: 824940 Size: SH
  7. Install 1 bolt to the manifold support bracket to exhaust manifold.

    8. Tighten
    Tighten the manifold support bracket bolt 50 N·m (37 lb ft).

  8. Install the exhaust manifold flange gasket.

    9. Object Number: 836734 Size: SH
  9. Install the following components to the exhaust manifold flange:
    10. • The springs (5)
    • 2 bolts (4)

    Tighten
    Tighten the exhaust pipe bolts to 43 N·m (32 lb ft).

  10. Install the exhaust pipe hangers (3).
  11. Connect the Heated Oxygen Sensor electrical connectors.
    12. • Connect the Heated Oxygen Sensor (HO2S2) electrical connector (2). Refer to Heated Oxygen Sensor 2 Replacement in Engine Controls - 1.8L (LV6) or Heated Oxygen Sensor 2 Replacement Engine Controls - 1.8L (LNK).
    • Connect the Heated Oxygen Sensor (HO2S1) electrical connector (1). Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 1.8L (LV6) or Heated Oxygen Sensor 1 Replacement Engine Controls - 1.8L (LNK).
  12. Lower the vehicle.

    13. 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.

  13. Connect the negative battery cable.