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How to Replace the Exhaust Manifold in a Pontiac Bonneville

The Pontiac Bonneville received its name for the Utah salt flats, the sight of many land speed records. Pontiac made Bonneville for 47 years. Throughout the longevity of its design life, the changes reflect the desires of the era's drivers. In 2004, Bonneville offered a 3.8L engine. The following steps detail the procedures for replacing the exhaust manifold on that engine.



Difficulty:
ChallengingInstructions
    Remove the Exhaust Manifold
  1. Step 1

    Disconnect the negative battery cable. Label the wires and their corresponding connections, then disconnect the spark plug wires.

  2. Step 2

    Take out the oil dipstick and remove the tube. Disconnect the left side lift bracket. Loosen the two bolts that attached the left exhaust manifold to the crossover pipe.

  3. Step 3

    Rock the manifold back and forth gently to loosen it from the cylinder head. Lift the exhaust manifold from the engine. Remove the gasket and discard it.

  4. Step 4

    Scrape old gasket material and debris from the mating surfaces. Wipe the surfaces with solvent. Check for damage.

  5. Install the Exhaust Manifold
  6. Step 1

    Position a new exhaust manifold gasket on the head. Set the exhaust manifold in place. Torque the studs in three even passes to 22 foot pounds.

  7. Step 2

    Install the two bolts that attach the left exhaust manifold to the cross over pipe. Tighten the bolts and torque them to 15 foot pounds.

  8. Step 3

    Replace the left side lift bracket, then set the oil dipstick tube and dipstick in place. Torque the bolts to 15 foot pounds.

  9. Step 4

    Reconnect the spark plug wires. Connect the negative battery cable to its terminal.

  10. Step 5

    Start the engine and allow it to run for several minutes. Check for exhaust leaks and proper engine operation.

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