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Home >> Pontiac >> 2003 >> Sunfire Automatic >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Exhaust Manifold Replacement >> Removal Procedure

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the exhaust manifold heat shield.
    Fig 1: Removing Exhaust Manifold Heat Shield
    G01581291Courtesy of GENERAL MOTORS CORP.
  3. Remove the oxygen sensor. Refer to OXYGEN SENSORS .
    Fig 2: Removing/Installing Heated Oxygen Sensor
    G01581292Courtesy of GENERAL MOTORS CORP.
  4. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
    NOTE: Do not bend the exhaust flex decoupler more than 3 degrees in any direction. Movement of more than 3 degrees will damage the exhaust flex decoupler.
  5. Remove the pipe to manifold nuts (3).
  6. Pull down and back on the exhaust pipe in order to disengage the pipe from the exhaust manifold.
    Fig 3: Disengaging Exhaust Pipe From Exhaust Manifold
    G01581293Courtesy of GENERAL MOTORS CORP.
  7. Lower the vehicle.
  8. Remove the exhaust manifold to cylinder head nuts.
  9. Remove the exhaust manifold.
    Fig 4: Removing/Installing Exhaust Manifold
    G01581294Courtesy of GENERAL MOTORS CORP.
  10. Clean all the sealing surfaces.
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