GM Corsica/Beretta 1988-1996 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION




CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

2.0L and 2.2L Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the oxygen sensor wire.
  4.  
  5. Remove the serpentine belt.
  6.  
  7. Remove the alternator-to-bracket bolts and support the alternator (with the wires attached) out of the way.
  8.  
  9. Raise and support the front of the vehicle.
  10.  
  11. Disconnect the exhaust pipe-to-exhaust manifold bolts and separate the pipe from the manifold, then carefully lower the vehicle.
  12.  
  13. Remove the oil fill tube.
  14.  
  15. For10993-96 vehicles, remove the heater outlet hose assembly nut from the exhaust manifold.
  16.  
  17. Remove the exhaust manifold retaining nuts/bolts.
  18.  
  19. Remove the exhaust manifold from the exhaust pipe flange and the manifold from the vehicle.
  20.  
  21. Remove and discard the gasket. Using a gasket scraper, thoroughly clean the gasket mounting surfaces.
  22.  



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Fig. Fig. 1: Exhaust manifold mounting - 2.0L and 2.2L (VIN G) engines

To install:
  1. Position a new exhaust manifold gasket, then install the manifold and secure using the retaining nuts/bolts.
  2.  
  3. Tighten the exhaust manifold-to-cylinder head nuts to 3-11 ft. lbs. (5-15 Nm) for10988-90 vehicles, and1015 inch lbs. (13 Nm) for10991-96 vehicles. Tighten the bolts to 6-13 ft. lbs. (8-18 Nm) for10988-90 vehicles, and studs to 89 inch lbs. (10 Nm) for10991-92 vehicles.
  4.  
  5. If removed, install the heater outlet hose assembly nut and tighten to108 ft. lbs. (4 Nm).
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Attach the exhaust pipe to the manifold, then carefully lower the vehicle.
  10.  
  11. Install the alternator and rear brace, if removed.
  12.  
  13. Install the serpentine drive belt.
  14.  
  15. Attach the oxygen sensor lead.
  16.  
  17. Connect the negative battery cable, then start the engine and check for leaks.
  18.  

2.3L Engine

See Figures 3, 4, 5 and 6

  1. Disconnect the negative battery cable.
  2.  
  3. Detach the oxygen sensor connector.
  4.  
  5. Remove the upper exhaust manifold heat shield.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove exhaust manifold brace-to-manifold bolt.
  10.  
  11. Remove the exhaust manifold-to-exhaust pipe spring loaded nuts by breaking each nut loose gradually, then remove the nuts.
  12.  
  13. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
  14.  
  15. Carefully lower the vehicle.
  16.  
  17. Unfasten the exhaust manifold-to-cylinder head attaching nuts, then remove the exhaust manifold.
  18.  
  19. Remove the lower exhaust manifold heat shield, seals and gaskets. Discard the gaskets, then thoroughly clean all of the gasket sealing surfaces.
  20.  



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Fig. Fig. 3: Exploded view of the exhaust manifold heat shields



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Fig. Fig. 4: Exhaust manifold brace mounting



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Fig. Fig. 5: Exploded view of the exhaust manifold and bolt tightening sequence -10990 2.3L engines



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Fig. Fig. 6: Exhaust manifold and gasket installation and bolt tightening sequence -10992-94 2.3L engines

To install:
  1. If installing a new exhaust manifold, transfer following components to the new manifold:
    1. Oxygen sensor (coat the threads of the sensor with a suitable anti-seize compound).
    2.  
    3. Bolt and nuts.
    4.  
    5. Lower heat shield.
    6.  
    7. Exhaust manifold studs.
    8.  

  2.  
  3. Position a new exhaust manifold gasket, then install the exhaust manifold and secure with the exhaust manifold-to-cylinder head attaching nuts. Tighten, in sequence, to 6-18 ft. lbs. (37-42 Nm).
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Install the exhaust manifold brace-to-manifold bolt.
  8.  
  9. Connect the exhaust pipe to the exhaust manifold flange.
  10.  
  11. Install the manifold to exhaust pipe bolts to the exhaust pipe flange. Tighten to10 ft. lbs. (9 Nm). Turn the nuts evenly to prevent binding.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Install the upper exhaust manifold heat shield.
  16.  
  17. Attach the oxygen sensor electrical connector.
  18.  
  19. Connect the negative battery cable.
  20.  

2.8L and 3.1L (VIN T) Engines

See Figures 7 and 8

LEFT SIDE
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the coolant fan.
  6.  
  7. Remove the heat shield.
  8.  
  9. Disconnect the exhaust crossover pipe from the manifold.
  10.  
  11. Unfasten the exhaust manifold-to-cylinder bolts, then remove the manifold from the vehicle.
  12.  
  13. Remove and discard the gaskets. Thoroughly clean the gasket mating surfaces.
  14.  

To install:
  1. Position a new gasket, then install the exhaust manifold. Loosely install the exhaust manifold-to-cylinder head bolts.
  2.  
  3. Attach the exhaust crossover pipe to the manifold.
  4.  
  5. Tighten the exhaust manifold-to-cylinder head bolts to10-9 ft lbs. (9-40 Nm) for10988 vehicles, or to108-21 ft. lbs. (4-7 Nm) for10989-93 vehicles.
  6.  
  7. Tighten the crossover bolts to108 ft. lbs. (4 Nm).
  8.  
  9. Install the heat shield and tighten the retaining nuts to 89 inch lbs. (10 Nm).
  10.  
  11. Install the coolant fan and the air cleaner assembly.
  12.  
  13. Connect the negative battery cable, then start the engine and check for exhaust leaks.
  14.  



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Fig. Fig. 7: Exhaust crossover attachment - 2.8L and 3.1L (VIN T) engines



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Fig. Fig. 8: Exploded view of the left and right side exhaust manifolds - 2.8L and 3.1L (VIN T) engines

RIGHT SIDE
  1. Remove the air cleaner assembly.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Disconnect the exhaust pipe at the crossover.
  8.  
  9. Carefully lower the vehicle.
  10.  
  11. Remove the heat shield.
  12.  
  13. Disconnect the crossover at the manifold.
  14.  
  15. Disconnect the accelerator and T.V. cables, then remove the cable bracket from the plenum.
  16.  
  17. Remove the oxygen sensor.
  18.  
  19. Unfasten the exhaust manifold bolts, then remove the exhaust manifold from the vehicle. Remove and discard the gasket. Thoroughly clean the gasket mating surfaces.
  20.  

To install:
  1. Position a new exhaust manifold gasket, then install the exhaust manifold. Loosely install the manifold retaining bolts.
  2.  
  3. Attach the crossover to the manifold.
  4.  
  5. Tighten the exhaust manifold-to-cylinder head bolts to104-1 ft. lbs. (20-9 Nm) for10988 vehicles and108-21 ft. lbs. (4-7 Nm) for10989-93 vehicles. Tighten the crossover pipe bolts to108 ft. lbs. (4 Nm).
  6.  
  7. Install the accelerator and T.V. cable bracket to the plenum, then connect the accelerator and T.V. cables.
  8.  
  9. Install the oxygen sensor.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Attach the exhaust pipe to the crossover, then carefully lower the vehicle.
  14.  
  15. Connect the negative battery cable, then install the air cleaner assembly.
  16.  
  17. Start the engine and check for leaks.
  18.  

3.1L VIN (M) Engines

See Figure 9

LEFT SIDE
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the top half of the air cleaner assembly and throttle cable duct.
  4.  
  5. Place a suitable drain pan under the radiator, then partially drain the cooling system.
  6.  
  7. Disconnect the radiator hose from the thermostat housing.
  8.  
  9. Disconnect the coolant bypass pipe from the water pump and exhaust manifold.
  10.  
  11. Remove the exhaust crossover heat shield, then disconnect the crossover pipe from the manifold.
  12.  
  13. Tag and disconnect the spark plug wires from the plugs.
  14.  
  15. Remove the exhaust manifold head shield.
  16.  
  17. Unfasten the exhaust manifold retaining nuts, then remove the manifold from the vehicle.
  18.  
  19. Remove and discard the gasket, then thoroughly clean the mating surfaces.
  20.  



Click image to see an enlarged view

Fig. Fig. 9: Exploded view of the exhaust manifold mounting - 3.1L (VIN M) engines

To install:
  1. Position a new exhaust manifold gasket, then install the manifold. Loosely install all of the manifold retaining nuts, then tighten them to102 ft. lbs. (16 Nm).
  2.  
  3. Install the exhaust manifold heat shield, then tighten the retaining nuts to 89 inch lbs. (10 Nm).
  4.  
  5. Fasten the exhaust crossover pipe to the manifold, then install the crossover pipe heat shield.
  6.  
  7. Connect the spark plug wires to the plugs, as tagged during removal.
  8.  
  9. Attach the coolant bypass pipe to the water pump and exhaust manifold.
  10.  
  11. Connect the radiator hose to the coolant outlet housing.
  12.  
  13. Install the top half of the air cleaner and throttle body duct.
  14.  
  15. Connect the negative battery cable, then start the engine and check for exhaust leaks.
  16.  

RIGHT SIDE
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the top half of the air cleaner assembly and throttle cable duct.
  4.  
  5. Remove the exhaust crossover heat shield, then disconnect the crossover from the exhaust manifold.
  6.  
  7. Remove the heated oxygen sensor.
  8.  
  9. Disconnect the EGR pipe from the exhaust manifold.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove the transaxle oil fill tube and dipstick assembly.
  14.  
  15. Disconnect the exhaust pipe from the manifold.
  16.  
  17. Detach the exhaust pipe from the converter flange, then support the converter with a suitable piece of wire.
  18.  
  19. Remove the converter heat shield from the body.
  20.  
  21. Remove the exhaust manifold heat shield.
  22.  
  23. Unfasten the exhaust manifold nuts, then remove the exhaust manifold from underneath the vehicle.
  24.  
  25. Remove and discard the gasket, then thoroughly clean the mating surfaces.
  26.  

To install:
  1. Position a new exhaust manifold gasket, then install the manifold. Loosely install the heat shield and the manifold retaining nuts
  2.  
  3. Tighten the exhaust manifold mounting nuts and tighten them to102 ft. lbs. (16 Nm).
  4.  
  5. Install the manifold heat shield nuts and tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Fasten the converter heat shield to the body.
  8.  
  9. Connect the exhaust pipe to the converter flange and the exhaust pipe to the exhaust manifold.
  10.  
  11. Install the transaxle oil fill tube and dipstick assembly.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Install the heated oxygen sensor.
  16.  
  17. Attach the crossover pipe to the exhaust manifolds. Install the crossover heat shield.
  18.  
  19. Connect the EGR pipe to the exhaust manifold.
  20.  
  21. Install the top half of the air cleaner assembly and throttle body duct.
  22.  
  23. Connect the negative battery cable, then start the engine and check for exhaust leaks
  24.  

See Figures 10 through 17



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Fig. Fig. 10: Disconnect the radiator hose from the thermostat housing



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Fig. Fig. 11: Unfasten the crossover heat shield retaining bolts ...



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Fig. Fig. 12: ... then remove the heat shield from the crossover pipe



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Fig. Fig. 13: Remove the crossover pipe-to-manifold retaining bolts



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Fig. Fig. 14: Remove the exhaust manifold heat shield



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Fig. Fig. 15: Unfasten the exhaust manifold retaining nuts ...



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Fig. Fig. 16: ... then remove the exhaust manifold from the vehicle



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Fig. Fig. 17: Remove and discard the exhaust manifold gasket

 
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