How to Replace the Exhaust Manifold in a Pontiac Grand Am

The Pontiac Grand Am was sold heavily to rental car companies. While sales were steady for the Grand Am over the years, it was discontinued in 2005. The following steps guide you through the installation of the exhaust manifold in the 3.1L and 3.4L left side engines that were available from 2001 until 2005.

Instructions

Remove the Exhaust Manifold

1

Disconnect the negative battery cable. Remove the air cleaner assembly, the throttle body duct and the exhaust crossover heat shield.

2

Pull the exhaust crossover pipe from the manifold. Disconnect the radiator hose from the thermostat housing.

3

Label and disconnect the spark plug wires. Take off the exhaust manifold heat shield. Remove the exhaust manifold fasteners and lift the manifold from the engine. Discard the gasket.

4

Clean the mating surfaces to remove any gasket material, dirt and carbon deposits. Wipe the surfaces with solvent. Check the mating surfaces for damage.

Install the Exhaust Manifold

5

Install the exhaust manifold with a new gasket. Torque the nuts in sequence to 12 foot pounds in three passes.

6

Set the exhaust manifold heat shield in place. Torque the nuts to 89 inch pounds. Connect the exhaust crossover pipe. Tighten the bolts to 18 foot pounds.

7

Place the crossover pipe heat shield in place. Torque the bolts to 89 inch pounds. Reconnect the spark plug wires and the radiator hose.

8

Reinstall the air cleaner assembly and the throttle body duct. Reconnect the negative battery cable to the terminal.

9

Start the engine and allow it to run for several minutes. Check for exhaust leaks. Make sure the engine is operating correctly.