Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement (2.2L - L61)

Removal Procedure





1. Remove the exhaust manifold heat shield.





2. Remove the oxygen sensor.
3. Raise and support the vehicle. Refer to Vehicle Lifting.





4. 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.

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





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

Installation Procedure





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





3. Notice: Refer to Fastener Notice in Service Precautions.

Important: Install the new exhaust nuts.

Install the new exhaust manifold to cylinder head retaining nuts. Follow the tightening sequence.
^ Tighten the nuts to 13 Nm (115 inch lbs.).
4. Raise and support the vehicle. Refer to Vehicle Lifting.





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

7. Important: Install the new exhaust nuts.

Install the retaining nuts which secure the manifold to the flex decoupler.
^ Tighten the nuts to 50 Nm (37 ft. lbs.).
8. Lower the vehicle.





9. Install the oxygen sensor.





10. Install the exhaust manifold heat shield.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).