Exhaust Manifold Replacement 2.4L

1. Disconnect the Oxygen sensor (O2S) connector.



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

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.




3. Remove the flex decoupler to exhaust manifold bolts.



4. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold.
5. Lower the vehicle.
6. Remove cruise control module and position aside. Refer to Cruise Control Module Replacement in Cruise Control.
7. Remove the exhaust manifold heat shield bolts and shield.
8. Remove oil level indicator. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical.
9. Remove the exhaust manifold nuts.
10. Remove the exhaust manifold and gasket.
11. Clean all sealing surfaces.

1. Install a new exhaust manifold gasket.
2. Install the exhaust manifold.




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.

3. Install the exhaust manifold nuts.

Tighten
Tighten the exhaust manifold nuts to 13 N·m (115 lb in).

4. Install oil level indicator tube and indicator. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical.



5. Install the exhaust manifold heat shield and bolts.

Tighten
Tighten the exhaust manifold heat shield bolts to 14 N·m (124 lb in).

6. Install cruise control module. Refer to Cruise Control Module Replacement in Cruise Control.
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



8. Install the flex decoupler to exhaust manifold bolts.

Tighten
Tighten the flex decoupler to exhaust manifold bolts to 35 N·m (26 lb ft).

9. Lower the vehicle.
10. Connect the Oxygen sensor (O2S) connector.

Exhaust Manifold Replacement 2.2L

1. Remove the oxygen sensor lead.
2. Remove the generator. Refer to Generator Replacement in Engine Electrical.
3. Remove the generator rear brace.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the exhaust pipe to the exhaust manifold.
6. Lower the vehicle.
7. Remove the oil fill tube. Refer to Oil Level Indicator and Tube Replacement .



8. Remove the exhaust manifold nuts.
9. Remove the exhaust manifold and the gasket.
10. Clean the mating surfaces at the cylinder head and the exhaust manifold.
11. Inspect the manifold for cracks, broken flanges and gasket surface damage.
12. Check the alignment of the exhaust manifold mating surfaces. Use a straight edge and a feeler gauge. If the flanges or the mating surfaces do not align, the manifold is warped and should be replaced.

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.

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.

3. Install the exhaust manifold nuts.

Tighten
Tighten the exhaust manifold nuts to 13 N·m (115 lb in).

4. Install the oil fill tube. Refer to Oil Level Indicator and Tube Replacement .
5. Raise the vehicle.
6. Install the exhaust pipe to the manifold. Refer to Intermediate Pipe Replacement .
7. Lower the vehicle.
8. Install the generator rear brace.
9. Install the generator. Refer to Generator Replacement in Engine Electrical.



10. Install the oxygen sensor lead.

Exhaust Manifold Replacement 2.2L (L61)

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



2. Remove the exhaust manifold heat shield.



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.




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

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




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.

Tighten
Tighten the nuts to 13 N·m (115 lb in).

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



5. Install a new exhaust manifold to flex coupler gasket (2).
6. Push the flex coupler into position on the exhaust manifold.

Important: Install the new exhaust nuts.

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

Tighten
Tighten the nuts to 30 N·m (22 lb ft).

8. Lower the vehicle.



9. Install the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls-2.2L (L61).



10. Install the exhaust manifold heat shield.

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.