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Exhaust Manifold Removal (with Secondary Air Injection)

WARNING: This page is about a different car, the 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View of Exhaust Manifold and Secondary Air Injection Bolts and Nuts
    GM2179163Courtesy of GENERAL MOTORS CORP.
  1. Remove the secondary air injection bolts (2) and nuts (1).
    2. Fig 2: View of Secondary Air Injection Studs
    GM2179164Courtesy of GENERAL MOTORS CORP.
  2. Remove the secondary air injection studs (3 and 4).
  3. Remove the secondary air injection valve assembly (1)
  4. Remove the secondary air injection gasket (2) and discard.
    5. Fig 3: View of Exhaust Manifold Heat Shield
    GM2179166Courtesy of GENERAL MOTORS CORP.
  5. Remove the exhaust manifold heat shield bolt (1).
  6. Remove the exhaust manifold heat shield (2).
    7. Fig 4: View Of Block Heater
    GM825111Courtesy of GENERAL MOTORS CORP.
  7. Remove the block heater if equipped.
    8. Fig 5: View of Oxygen Sensor
    GM2179167Courtesy of GENERAL MOTORS CORP.
  8. Remove the oxygen sensor (1).
    9. Fig 6: Exhaust Manifold Brace And Bolts
    GM2179168Courtesy of GENERAL MOTORS CORP.
  9. Remove the exhaust manifold brace bolts (2) and brace (1).
    10. Fig 7: View of Exhaust Manifold to Cylinder Head Retaining Nuts
    GM2179169Courtesy of GENERAL MOTORS CORP.
  10. Remove and discard the exhaust manifold to cylinder head retaining nuts (3).
  11. Remove the exhaust manifold (1).
  12. Remove the exhaust manifold gasket (2).
  13. Clean all of the sealing surfaces.
  14. If the exhaust manifold is being replaced, transfer the following parts:
    • The exhaust manifold heat shield
    • The oxygen sensor
    15. Fig 8: View of Secondary Air Injection Pipe Assembly Bolts
    GM2179170Courtesy of GENERAL MOTORS CORP.
  15. Remove the secondary air injection pipe assembly bolts (2).
  16. Remove the secondary air injection pipe assembly (1).
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