Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement (L61/LE5)

Removal Procedure





1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (Exhaust Manifold Heat Shield Replacement) .
2. Remove the pre catalyst heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor 1 Replacement (Service and Repair) for the 2.2L (L61) engine or Heated Oxygen Sensor 1 Replacement (Service and Repair) for the 2.4L engine.
3. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LE5/L61) (Catalytic Converter Replacement (LE5/L61))Catalytic Converter Replacement (LNF) (Catalytic Converter Replacement (LNF-2.0L)) .
4. Remove and discard the exhaust manifold nuts.
5. Remove the exhaust manifold.
6. Remove and discard the exhaust manifold gasket.
7. Clean the sealing surface of the engine block.



Installation Procedure





1. Install a NEW exhaust manifold gasket onto the studs.
2. Install the exhaust manifold.





Notice: Refer to Fastener Notice (Fastener Notice) .


Important: Install the new exhaust nuts.


3. Install NEW exhaust manifold nuts.

Tighten the nuts in the sequence shown to 14 N.m (10 lb ft).

4. Install the catalytic converter. Refer to Catalytic Converter Replacement (LE5/L61) (Catalytic Converter Replacement (LE5/L61))Catalytic Converter Replacement (LNF) (Catalytic Converter Replacement (LNF-2.0L)) .
5. Install the pre catalyst HO2S. Refer to Heated Oxygen Sensor 1 Replacement (Service and Repair) for the 2.2L (L61) engine or Heated Oxygen Sensor 1 Replacement (Service and Repair) for the 2.4L engine.
6. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (Exhaust Manifold Heat Shield Replacement) .