Solstice 2006-2008, Sky 2007-2008

Exhaust Manifold

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Removal & Installation



2.0L (LNF) 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 (LNF) 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.  

2.4L (LE5) Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the exhaust manifold heat shield bolts.
  4.  
  5. Remove the exhaust manifold heat shield.
  6.  
  7. Remove the block heater if equipped.
  8.  
  9. Remove the oxygen sensor.
  10.  
  11. Remove and discard the exhaust manifold to cylinder head retaining nuts.
  12.  
  13. Remove the exhaust manifold.
  14.  
  15. If the exhaust manifold is being replaced, transfer the following parts:

    The exhaust manifold heat shield
     
    The oxygen sensor

    Click image to see an enlarged view

    Fig. Exhaust manifold removal



    Click image to see an enlarged view

    Fig. Exhaust manifold torque sequence

     

  16.  

To install:


NOTE
Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. An improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance. Remove the oxygen sensor prior to cleaning the manifold, do not submerge the oxygen sensor in cleaning solvent.

  1. Remove the oxygen sensor from the manifold.
  2.  
  3. Clean the exhaust manifold in solvent.
    CAUTION
    Wear safety glasses in order to avoid eye damage.

  4.  
  5. Dry the exhaust manifold with compressed air.
  6.  
  7. Inspect the heat shield for damage.
  8.  
  9. Use a straightedge and a feeler gage and measure the exhaust manifold mounting face for warpage. An exhaust manifold face with warpage in excess of 0.010 inch. (0.25 mm) may cause an exhaust leak and may affect OBD II system performance. Exhaust manifolds not within specifications must be replaced.
  10.  
  11. Install new exhaust manifold studs. Tighten the studs to 89 inch. lbs. (10 Nm).
  12.  
  13. Install the exhaust manifold gasket.
  14.  
  15. Install the exhaust manifold to the cylinder head.
  16.  
  17. Install NEW exhaust manifold to cylinder head retaining nuts finger tight.
  18.  
  19. Tighten the NEW exhaust manifold to cylinder head retaining nuts in sequence. Tighten the nuts to 10 ft. lbs. (14 Nm).
  20.  
  21. Coat the threads of the oxygen sensor with anti-seize P/N 12397953, or equivalent.
  22.  
  23. Install the oxygen sensor. Tighten the oxygen sensor to 31 ft. lbs. (42 Nm).
  24.  
  25. Install the exhaust manifold heat shield.
  26.  
  27. Install the exhaust manifold heat shield bolts. Tighten the bolts to 16 ft. lbs. (22 Nm).
  28.  

 
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