Exhaust Manifold: Service and Repair

Exhaust Manifold Replacement (2.2L Engine)

Removal Procedure





1. Remove the connector position assurance (CPA) retainer (1).
2. Disconnect the heated oxygen sensor (HO2S) electrical connector (2).





3. Important: The HO2S uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

Remove the HO2S.





4. Remove the exhaust manifold heat shield bolts.
5. Remove the heat shield.
6. Remove the intermediate pipe.





7. Remove and discard the exhaust manifold nuts.
8. Remove the exhaust manifold/catalytic converter assembly.
9. Remove and discard the exhaust manifold gasket.

Installation Procedure





1. Install a NEW exhaust manifold gasket on the cylinder head.
2. Install the exhaust manifold/catalytic converter assembly.
3. Install the exhaust manifold nuts finger tight.





4. Notice: Refer to Fastener Notice in Service Precautions.

Tighten the exhaust manifold nuts in the sequence shown.
^ Tighten the nuts to 14 Nm (10 ft. lbs.).
5. Install the intermediate pipe.





6. Install the heat shield.
7. Install the exhaust manifold heat shield bolts.
^ Tighten the bolts to 23 Nm (17 ft. lbs.).





8. Install the HO2S.
^ Tighten the sensor to 42 Nm (31 ft. lbs.).





9. Connect the HO2S electrical connector.
10. Install the CPA retainer.
11. Start the vehicle and inspect for leaks.