Exhaust Manifold Replacement 2.4L

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



2. Remove the upper heat shield.



3. Disconnect the Oxygen (O2S) sensor connector.
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 fasteners which secure the manifold to the exhaust flex decoupler.



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 retaining nuts which secure the exhaust manifold to the cylinder head.
9. Remove the following components:

•	The exhaust manifold

•

The seals

•	The gaskets

10. 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 in the sequence shown.

Tighten
Tighten the exhaust manifold nuts to 13 N·m (110 lb in).

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



5. Install the fasteners which secure the manifold to the flex decoupler.

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

6. Lower the vehicle.



7. Install the exhaust manifold heat shield.

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

8. Coat the threads of the oxygen sensor (O2S) connector with anti-seize compound GM P/N 5613695 or equivalent.



9. Connect the oxygen sensor (O2S) connector.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.