Aveo 2004-2005

Exhaust Manifold

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Removal & Installation




NOTE
Spray the exhaust system fasteners with penetrating lubricant before removing them to help prevent broken studs and bolts. The use of a 6-point socket is highly recommended when removing exhaust system fasteners.


CAUTION
To prevent serious burns, allow the exhaust manifold to cool down before attempting to remove it.

  1. Remove or disconnect the following:

    Negative battery cable
     
    Oxygen sensor connector
     
    Manifold heat shield
     
    Exhaust pipes
     
    Exhaust manifold nuts in the sequence shown. See Figure 6.
     
    Exhaust manifold

    Click image to see an enlarged view

    Fig. Exhaust manifold bolt removal sequence-1.6L engine



    Click image to see an enlarged view

    Fig. Exhaust manifold bolt installation sequence-2004 1.6L engine



    Click image to see an enlarged view

    Fig. Exhaust manifold bolt installation sequence-2005 1.6L engine

     

  2.  

To install:

  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. Install a new exhaust manifold gasket and the exhaust manifold on the cylinder head. Start 2 nuts to hold the manifold in position. Tighten the nuts in sequence to 18 ft. lbs. (25 Nm).
  4.  
  5. Remove or disconnect the following:

    Exhaust pipes. Tighten the nuts to 30 ft. lbs. (40 Nm).
     
    Heat shield
     
    Oxygen sensor
     
    Negative battery cable
     

  6.  


NOTE
Spray the exhaust system fasteners with penetrating lubricant before removing them to help prevent broken studs and bolts. The use of a 6-point socket is highly recommended when removing exhaust system fasteners.


CAUTION
To prevent serious burns, allow the exhaust manifold to cool down before attempting to remove it.

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the oxygen sensor connector
  4.  
  5. Remove the exhaust manifold heat shield
  6.  
  7. Remove the nuts that connect the exhaust manifold to the auxiliary catalytic converter.
  8.  
  9. Remove the exhaust manifold nuts in the sequence shown.
  10.  
  11. Remove the exhaust manifold and gasket.

    Click image to see an enlarged view

    Fig. Exhaust manifold bolt removal sequence-1.6L engine

  12.  

To install:

  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. Install a new exhaust manifold gasket and the exhaust manifold on the cylinder head. Start 2 nuts to hold the manifold in position. Tighten the nuts in sequence to 18 ft. lbs. (25 Nm).

    Click image to see an enlarged view

    Fig. Exhaust manifold bolt installation sequence-1.6L engine

  4.  
  5. Install the nuts that connect the exhaust manifold to the auxiliary catalytic converter. Tighten the nuts to 30 ft. lbs. (40 Nm).
  6.  
  7. Install the exhaust manifold heat shield and tighten the bolts to 11 ft. lbs. (15 Nm).
  8.  
  9. Connect the oxygen sensor connector.
  10.  
  11. Connect the negative battery cable.
  12.  

 
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