GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 Engine 🢒 Engine Electrical 🢒 Exhaust Manifold Replacement

Removal Procedure

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

    2. Object Number: 412121 Size: SH
  2. Remove the oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 2.2L (L61).
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    4. Object Number: 878834 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.

  4. 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. Object Number: 746061 Size: SH
  7. Remove the exhaust manifold to cylinder head nuts.
  8. Remove the exhaust manifold.
  9. 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. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 60046 Size: SH

    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 13 N·m (115 lb in).

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

    5. Object Number: 878834 Size: SH
  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.

  7. Install the retaining nuts which secure the manifold to the flex decoupler .

    8. Tighten
    Tighten the nuts to 50 N·m (37 lb ft).

  8. Lower the vehicle.

    9. Object Number: 412121 Size: SH
  9. Install the oxygen sensor. Refer to Heated Oxygen Sensor 1 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).