Replacing Exhaust Manifold on Chevrolet 2.2L?

Exhaust Manifold

REMOVAL & INSTALLATION

2.4L Engines

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the intake manifold cover:
   1. Remove the engine oil fill cap.
   2. Grasp the intake manifold cover by the lower right inboard corner and pull up to disengage the cover from the stud.
   3. Grasp the intake manifold cover by the upper left corner and pull up to disengage the cover from the stud.
   4. Remove the intake manifold cover.
3. Remove the exhaust manifold heat shield studs.
4. Remove the exhaust manifold heat shield.
5. If equipped with Regular Production Option (RPO) MN5, remove the Heated Oxygen Sensor (HO2S) Connector Position Assurance (CPA) retainer.
6. Disconnect the engine harness electrical connector from the HO2S.
7. Remove the HO2S clip from the thermostat housing.
8. If equipped with RPO M86, remove the HO2S CPA retainer.
9. Disconnect the engine harness electrical connector from the HO2S.
10. Remove the HO2S clip from the thermostat housing.
11. Remove the HO2S.
12. 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.
13. Remove the catalytic converter to exhaust manifold nuts.
14. Pull down and back on the exhaust pipe in order to separate the catalytic converter from the exhaust manifold.
15. Remove and discard the catalytic converter gasket.
16. Lower the vehicle.
17. Remove the exhaust manifold nuts.
18. Remove the exhaust manifold.
19. Remove and discard the exhaust manifold gasket.
20. Clean and inspect all gasket mating surfaces.
    
    
    

    

    Fig. Exhaust manifold removal-2.4L Engine

To install:

1. Install a NEW exhaust manifold gasket onto the studs.
2. Install the exhaust manifold.
3. Install NEW exhaust manifold nuts. Tighten the nuts in the sequence shown to 10 ft. lbs. (14 Nm).
   
   
   

   

   Fig. Exhaust manifold torque sequence-2.4L Engine
4. Raise and support the vehicle.
5. Install a NEW catalytic converter gasket.
6. Install the catalytic converter to the exhaust manifold studs.
7. Install the catalytic converter to exhaust manifold nuts. Tighten the nuts to 37 ft. lbs. (50 Nm).
8. Lower the vehicle.
9. If reinstalling the old HO2S, coat the threads with anti-seize compound or equivalent.
10. Install the HO2S. Tighten the sensor to 31 ft. lbs. (42 Nm).
11. If equipped with RPO M86, connect the engine harness electrical connector to the HO2S.
12. Install the HO2S clip to the thermostat housing.
13. Install the HO2S CPA retainer.
14. If equipped with RPO MN5, connect the engine harness electrical connector to the HO2S.
15. Install the HO2S clip from the thermostat housing.
16. Install the HO2S CPA retainer.
17. Install the exhaust manifold heat shield.
18. Install the exhaust manifold heat shield studs. Tighten the studs to 16 ft. lbs. (22 Nm).
19. Install the intake manifold cover:
    1. Place the intake manifold cover onto the engine over the studs.
    2. Push down on the intake manifold cover directly over the lower right stud in order to engage the cover to the stud.
    3. Push down on the intake manifold cover directly over the upper left stud in order to engage the cover to the stud.
    4. Install the engine oil fill cap.
    
    
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