HHR 2006-2008

Exhaust Manifold

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the turbocharger. Refer to turbocharger removal.
  4.  
  5. Remove the exhaust manifold heat shield bolts.
  6.  
  7. Remove the heat shield.
  8.  
  9. Remove and discard the exhaust manifold nuts.
  10.  
  11. Remove the exhaust manifold.
  12.  
  13. Remove and discard the exhaust manifold gasket.
  14.  

To install:

Click image to see an enlarged view

Fig. Exhaust manifold tightening sequence 2.0L engine

  1. Install a new exhaust manifold gasket onto the studs.
  2.  
  3. Install the exhaust manifold.
  4.  
  5. Install the new exhaust manifold nuts.
  6.  
  7. Tighten the exhaust manifold nuts in the sequence shown to 10 ft. lbs. (14 Nm).
  8.  
  9. Install the heat shield.
  10.  
  11. Install the exhaust manifold heat shield bolts and tighten to 18 ft. lbs. (25 Nm).
  12.  
  13. Install the turbocharger.
  14.  

2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the exhaust manifold heat shield.
    WARNING
    The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor.


    WARNING
    The use of excessive force may damage the threads in the exhaust manifold/pipe.


    NOTE
    The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the oxygen sensor.


    NOTE
    The oxygen sensor may be difficult to remove when the engine temperature is less than 120°F (48°C).

  4.  
  5. Remove the oxygen sensor.
  6.  
  7. Raise and support the vehicle.
    WARNING
    Do not bend the exhaust flex decoupler more than 3° in any direction. Movement of more than 3° will damage the exhaust flex decoupler.

  8.  
  9. Remove the pipe to manifold nuts.
  10.  
  11. Pull down and back on the exhaust pipe in order to disengage the pipe from the exhaust manifold.
  12.  
  13. Lower the vehicle.
  14.  
  15. Remove the exhaust manifold to cylinder head nuts.
  16.  
  17. Remove the exhaust manifold.
  18.  
  19. Clean all the sealing surfaces.
  20.  

To install:

Click image to see an enlarged view

Fig. Exhaust manifold torque sequence-2.2L engine

  1. Install a new exhaust manifold gasket.
  2.  
  3. Install the exhaust manifold to the cylinder head.
    NOTE
    Install the new exhaust nuts.

  4.  
  5. Install the new exhaust manifold to cylinder head retaining nuts. Follow the tightening sequence. Tighten the nuts to 115 inch lbs. (13 Nm ).
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Install a new exhaust manifold to flex coupler gasket.
  10.  
  11. Push the flex coupler into position on the exhaust manifold.
    NOTE
    Install the new exhaust nuts.

  12.  
  13. Install the retaining nuts which secure the manifold to the flex decoupler. Tighten the nuts to 37 ft. lbs. (50 Nm).
  14.  
  15. Lower the vehicle.
    NOTE
    A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound applied to the threads. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation.

  16.  
  17. Coat the threads of the oxygen sensor with anti-seize compound Saturn P/N 21485279, if necessary.
  18.  
  19. Install the oxygen sensor. Tighten the oxygen sensor to 22 ft. lbs. (30 Nm)
  20.  
  21. Install the exhaust manifold heat shield. Tighten the bolts to 18 ft. lbs. (25 Nm).
  22.  

2.4L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the intake manifold cover:
    1. Remove the engine oil fill cap.
    2.  
    3. Grasp the intake manifold cover by the lower right inboard corner and pull up to disengage the cover from the stud.
    4.  
    5. Grasp the intake manifold cover by the upper left corner and pull up to disengage the cover from the stud.
    6.  
    7. Remove the intake manifold cover.
    8.  

  4.  
  5. Remove the exhaust manifold heat shield studs.
  6.  
  7. Remove the exhaust manifold heat shield.
  8.  
  9. If equipped with Regular Production Option (RPO) MN5, remove the Heated Oxygen Sensor (HO2S) Connector Position Assurance (CPA) retainer.
  10.  
  11. Disconnect the engine harness electrical connector from the HO2S.
  12.  
  13. Remove the HO2S clip from the thermostat housing.
  14.  
  15. If equipped with RPO M86, remove the HO2S CPA retainer.
  16.  
  17. Disconnect the engine harness electrical connector from the HO2S.
  18.  
  19. Remove the HO2S clip from the thermostat housing.
  20.  
  21. Remove the HO2S.
  22.  
  23. Raise and support the vehicle.
    WARNING
    Do not bend the exhaust flex decoupler more than 3° in any direction. Movement of more than 3° will damage the exhaust flex decoupler.

  24.  
  25. Remove the catalytic converter to exhaust manifold nuts.
  26.  
  27. Pull down and back on the exhaust pipe in order to separate the catalytic converter from the exhaust manifold.
  28.  
  29. Remove and discard the catalytic converter gasket.
  30.  
  31. Lower the vehicle.
  32.  
  33. Remove the exhaust manifold nuts.
  34.  
  35. Remove the exhaust manifold.
  36.  
  37. Remove and discard the exhaust manifold gasket.
  38.  
  39. Clean and inspect all gasket mating surfaces.

    Click image to see an enlarged view

    Fig. Exhaust manifold removal-2.4L Engine

  40.  

To install:

  1. Install a NEW exhaust manifold gasket onto the studs.
  2.  
  3. Install the exhaust manifold.
  4.  
  5. Install NEW exhaust manifold nuts. Tighten the nuts in the sequence shown to 10 ft. lbs. (14 Nm).

    Click image to see an enlarged view

    Fig. Exhaust manifold torque sequence-2.4L Engine

  6.  
  7. Raise and support the vehicle.
  8.  
  9. Install a NEW catalytic converter gasket.
  10.  
  11. Install the catalytic converter to the exhaust manifold studs.
  12.  
  13. Install the catalytic converter to exhaust manifold nuts. Tighten the nuts to 37 ft. lbs. (50 Nm).
  14.  
  15. Lower the vehicle.
  16.  
  17. If reinstalling the old HO2S, coat the threads with anti-seize compound or equivalent.
  18.  
  19. Install the HO2S. Tighten the sensor to 31 ft. lbs. (42 Nm).
  20.  
  21. If equipped with RPO M86, connect the engine harness electrical connector to the HO2S.
  22.  
  23. Install the HO2S clip to the thermostat housing.
  24.  
  25. Install the HO2S CPA retainer.
  26.  
  27. If equipped with RPO MN5, connect the engine harness electrical connector to the HO2S.
  28.  
  29. Install the HO2S clip from the thermostat housing.
  30.  
  31. Install the HO2S CPA retainer.
  32.  
  33. Install the exhaust manifold heat shield.
  34.  
  35. Install the exhaust manifold heat shield studs. Tighten the studs to 16 ft. lbs. (22 Nm).
  36.  
  37. Install the intake manifold cover:
    1. Place the intake manifold cover onto the engine over the studs.
    2.  
    3. Push down on the intake manifold cover directly over the lower right stud in order to engage the cover to the stud.
    4.  
    5. Push down on the intake manifold cover directly over the upper left stud in order to engage the cover to the stud.
    6.  
    7. Install the engine oil fill cap.
    8.  

  38.  

 
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