Chevrolet Cobalt Service & Repair Manual: Exhaust Manifold Gasket R&R

1. Remove the secondary air injection bolts (2) and nuts (1), Fig. 1.
2. Remove the secondary air injection studs (3 and 4), Fig. 2.
3. Remove the secondary air injection valve assembly (1), Fig. 2.
4. Remove the secondary air injection gasket (2) and discard, Fig. 2.
5. Remove the exhaust manifold heat shield bolt.
6. Remove the exhaust manifold heat shield.
7. Remove the block heater if equipped.
8. Remove the oxygen sensor.
9. Remove the exhaust manifold brace bolts (2) and brace (1), Fig. 3.
10. Remove and discard the exhaust manifold to cylinder head retaining nuts (3), Fig. 4.
11. Remove the exhaust manifold (1), Fig. 4.
12. Remove the exhaust manifold gasket (2), Fig. 4.
13. Clean all of the sealing surfaces.
14. If the exhaust manifold is being replaced, transfer the following parts: The exhaust manifold heat shield and the oxygen sensor.
15. Remove the secondary air injection pipe assembly bolts (2), Fig. 5.
16. Remove the secondary air injection pipe assembly (1), Fig. 5.
17. Reverse procedure to install, noting the following:
  a. Torque exhaust manifold studs to 89 inch lbs.
  b. Torque secondary air injection pipe assembly bolts to 89 inch lbs.
  c. Torque exhaust manifold brace bolts to 43 ft. lbs.
  d. Torque new exhaust manifold to cylinder head nuts in sequence to 124 inch lbs.
  e. Torque oxygen sensor to 31 ft. lbs.
  f. Torque block heater to 89 inch lbs.
  g. Torque exhaust manifold heat shield bolt to 18 ft. lbs.
  h. Torque secondary air injection studs to 89 inch lbs.

Fig. 1 Secondary air injection fasteners

Fig. 2 Secondary air injection replacement

Fig. 3 Exhaust manifold brace replacement

Fig. 4 Exhaust manifold replacement

Fig. 5 Secondary air injection pipe assembly

    Engine, Replace
    Removal 1. Open and support hood. Install suitable protective covering over fenders. Mark upper hood hinge location to hood with suitable grease pencil. Remove ...

    Exhaust Manifold, Replace
    Removal 1. Remove exhaust manifold heat shield. 2. Remove oxygen sensor. 3. Raise and support vehicle. ...

    See also:

    Chevrolet Cobalt Owners Manual. Before Leaving on a Long Trip
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    Chevrolet Cobalt Owners Manual

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