Friday, October 14, 2011

How to replace Exhaust Manifold on 2.2L Chevrolet ?


Exhaust Manifold



REMOVAL & INSTALLATION


2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the exhaust manifold heat shield.
    WARNING
    The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor.


    WARNING
    The use of excessive force may damage the threads in the exhaust manifold/pipe.


    NOTE
    The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the oxygen sensor.


    NOTE
    The oxygen sensor may be difficult to remove when the engine temperature is less than 120°F (48°C).
  3. Remove the oxygen sensor.
  4. Raise and support the vehicle.
    WARNING
    Do not bend the exhaust flex decoupler more than 3° in any direction. Movement of more than 3° will damage the exhaust flex decoupler.
  5. Remove the pipe to manifold nuts.
  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.
To install:
Click image to see an enlarged view
Fig. Exhaust manifold torque sequence-2.2L engine
  1. Install a new exhaust manifold gasket.
  2. Install the exhaust manifold to the cylinder head.
    NOTE
    Install the new exhaust nuts.
  3. Install the new exhaust manifold to cylinder head retaining nuts. Follow the tightening sequence. Tighten the nuts to 115 inch lbs. (13 Nm ).
  4. Raise and support the vehicle.
  5. Install a new exhaust manifold to flex coupler gasket.
  6. Push the flex coupler into position on the exhaust manifold.
    NOTE
    Install the new exhaust nuts.
  7. Install the retaining nuts which secure the manifold to the flex decoupler. Tighten the nuts to 37 ft. lbs. (50 Nm).
  8. Lower the vehicle.
    NOTE
    A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound applied to the threads. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation.
  9. Coat the threads of the oxygen sensor with anti-seize compound Saturn P/N 21485279, if necessary.
  10. Install the oxygen sensor. Tighten the oxygen sensor to 22 ft. lbs. (30 Nm)
  11. Install the exhaust manifold heat shield. Tighten the bolts to 18 ft. lbs. (25 Nm).


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