ION, L-Series, S-Series 1999-2005

Exhaust Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Do not bend the flex coupling more than 3 degrees in any direction to avoid damage.



    Negative battery cable
     
    Exhaust manifold heat shield
     
    Oxygen Sensor (O 2 S) from the manifold
     



    Pipe-to-manifold nuts, pull down and back on the pipe in order to separate the pipe from the manifold
     
    Exhaust pipe from the manifold
     
    Exhaust manifold-to-head nuts
     
    Exhaust manifold

    Click image to see an enlarged view

    Fig. Remove the exhaust manifold and gasket-ION models

     

  4.  

To install:

Click image to see an enlarged view

Fig. Tighten the exhaust manifold nuts in the sequence shown-2.0L ION models



Click image to see an enlarged view

Fig. Tighten the exhaust manifold nuts in the sequence shown-2.2L ION models

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts in the sequence illustrated, to 115 inch lbs. (13 Nm)
     
    New manifold-to-flex pipe gasket, and place the pipe in position. Tighten the nuts to 32 ft. lbs. (43 Nm) on 2.2L engines or 37 ft. lbs. (50 Nm) on 2.0L engines.
     
    O 2 S
     
    Exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  2.  
  3. Start the vehicle and check for leaks, repair if necessary.
  4.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Do not bend the flex coupling more than 3 degrees in any direction to avoid damage.



    Negative battery cable
     
    Exhaust manifold heat shield
     
    Oxygen Sensor (O 2 S) from the manifold
     



    Pipe-to-manifold nuts, pull down and back on the pipe in order to separate the pipe from the manifold
     
    Exhaust pipe from the manifold
     
    Exhaust manifold-to-head nuts
     
    Exhaust manifold

    Click image to see an enlarged view

    Fig. Remove the exhaust manifold and gasket-ION models

     

  4.  

To install:

Click image to see an enlarged view

Fig. Tighten the exhaust manifold nuts in the sequence shown-2.0L ION models



Click image to see an enlarged view

Fig. Tighten the exhaust manifold nuts in the sequence shown-2.2L ION models

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts in the sequence illustrated, to 115 inch lbs. (13 Nm)
     
    New manifold-to-flex pipe gasket, and place the pipe in position. Tighten the nuts to 32 ft. lbs. (43 Nm) on 2.2L engines or 37 ft. lbs. (50 Nm) on 2.0L engines.
     
    O 2 S
     
    Exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  2.  
  3. Start the vehicle and check for leaks, repair if necessary.
  4.  

 
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