Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.

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

Fig 1: View Of Exhaust Manifold & Gasket
Courtesy of GENERAL MOTORS CORP.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

IMPORTANT: Install new exhaust nuts.
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).

Fig 2: Identifying Exhaust Manifold Nuts Tightening Sequence
Courtesy of GENERAL MOTORS CORP.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Install a new exhaust manifold to flex coupler gasket (2).
Push the flex coupler into position on the exhaust manifold.
IMPORTANT: Install new exhaust nuts.
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).

Fig 3: Locating Exhaust Manifold To Flex Decoupler Nuts
Courtesy of GENERAL MOTORS CORP.
Lower the vehicle.
Install the oxygen sensor. Refer to Heated Oxygen Sensor (HO2S) Replacement (Pre Catalytic Converter) or Heated Oxygen Sensor (HO2S) Replacement (Post Catalytic Converter) in Engine Controls-2.2L (L61).

Fig 4: Oxygen Sensor & Harness Connector
Courtesy of GENERAL MOTORS CORP.
Install the exhaust manifold heat shield.
Tighten: Tighten the bolts to 25 N.m (18 lb ft).

Fig 5: Removing & Installing Exhaust Manifold Heat Shield
Courtesy of GENERAL MOTORS CORP.
Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.