Alero, Grand Am 1999-2005

Exhaust Manifold

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold heat shield
     
    Oxygen (O 2 S) sensor
     
    Manifold to the exhaust flex decoupler retainers
     

  4.  
  5. Pull down and back on the exhaust pipe in order to disconnect the pipe from the exhaust manifold.

    Exhaust manifold to cylinder head retaining nuts
     
    Exhaust manifold and gasket

    Click image to see an enlarged view

    Fig. Remove the exhaust manifold-2.2L engine

     

  6.  

To install:

  1. Install or connect the following:

    New exhaust manifold gasket
     
    Exhaust manifold and tighten the retainers in sequence to 106 inch lbs. (12 Nm)
     
    New exhaust manifold to flex coupler gasket
     

  2.  
  3. Push the flex coupler into position on the exhaust manifold.

    Retaining nuts and tighten to 26 ft. lbs. (35 Nm)
     
    O 2 S sensor
     
    Exhaust manifold heat shield and tighten the bolts to 18 ft. lbs. (25 Nm)
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Tighten the exhaust manifold retainers in this sequence-2.2L engine

     

  4.  

3.1L & 3.4L Engines
Left Side
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Partially drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Throttle body duct
     
    Exhaust crossover heat shield
     
    Exhaust crossover pipe from the manifold
     
    Radiator hose from the thermostat housing
     
    Spark plug wires
     
    Exhaust manifold heat shield
     
    Exhaust manifold

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold mounting-3.1L & 3.4L engines

     

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket. Torque the nuts to 12 ft. lbs. (16 Nm).
     
    Exhaust manifold heat shield. Torque the nuts to 89 inch lbs. (10 Nm).
     
    Exhaust crossover pipe. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Crossover pipe heat shield. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Spark plug wires
     
    Radiator hose to the coolant outlet housing
     
    Air cleaner assembly
     
    Throttle body duct
     
    Negative battery cable
     

  2.  

Right Side
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Throttle body duct
     
    Heated Oxygen Sensor (HO 2 S)
     
    Exhaust crossover heat shield
     
    Exhaust Gas Recirculation (EGR) pipe from the exhaust manifold
     
    Exhaust crossover pipe
     
    Exhaust manifold heat shield
     
    Transaxle oil fill tube
     
    Front exhaust pipe from the exhaust manifold
     
    Wires from the spark plugs
     
    Exhaust manifold
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket. Torque the nuts to 12 ft. lbs. (16 Nm).
     
    Exhaust manifold heat shield. Torque the nuts to 89 inch lbs. (10 Nm).
     
    Exhaust crossover pipe to the manifold. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Exhaust crossover pipe heat shield. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Exhaust pipe to the exhaust manifold. Torque the bolts to 33 ft. lbs. (45 Nm).
     
    Transaxle oil level indicator and fill tube assembly
     
    HO 2 S
     
    EGR pipe to the exhaust manifold
     
    Exhaust crossover heat shield
     
    Throttle body duct
     
    Air cleaner assembly
     
    Negative battery cable
     

  2.  

These vehicles were filled at the factory with an antifreeze/coolant called GM Goodwrench DEX-COOL®. When adding coolant to vehicles, it is important that you use GM Goodwrench DEX-COOL (orange-colored, silicate-free) coolant. Propylene glycol is not recommended for use in GM vehicles . A 50/50 mixture of DEX-COOL and clean water will provide all the recommended protection. DO NOT mix DEX-COOL with any other type of antifreeze .

 
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