hi guys, I had a question. Has anyone replaced the exhaust manifold on a HHR with a 2.2 liter engine? I'm going to tackle this problem this week, & I want to know what I was in for. I used to be a mechanic years ago, it looks fairly straightforward but I want to know if there's any tips or tricks or anything I should know.any input would be appreciated! Thanks!

 

I have avoided doing it by finding a bad basket and a cracked flex pipe. Be sure before you commit.

Be prepared with new studs and nuts. And knuckle medicine.

 

thanks for the reply, yes I replaced and welded a cracked flex pipe first and then I noticed that there was a crack in the manifold.

 

thanks for the reply, yes I replaced and welded a cracked flex pipe first and then I noticed that there was a crack in the manifold.should I anticipate problems with the studs on the manifold? I was figuring since this is an 09, it wouldn't be that big of a problem. I have done numerous old vehicles with problems, but I was hoping this would be different!

 

I thought that I saw a crack in my manifold, turns out there are gaps between the bolt holes.

Always assume at least one stud will break or strip or misbehave. Steel studs in aluminum allow plus heat plus corrosive gas equals trouble.

You did mean you welded a new flex joint in, I hope. If you tried to weld the original, it has failed.

 

hello again, yes I did weld a new flex pipe on. That old piece of crap flex pipe would definitely fail again if I welded it. thanks again for your help, I was hoping this manifold would be uneventful, but I guess I'll see and be prepared for the worst!

 

That's correct.

I recently talked to a GM Powertrain engineer at a local car show. The local GM Powertrain plant in Tonawanda, NY had set up a display of the engines they produce at the plant, which includes the 2.4 and 2.5 Ecotec.

The engineer said they designed the gaps in the exhaust manifold to prevent the heat stress cracking that often occurs in those areas.

My 8.1L Vortec in the Suburban has the same gaps in the exhaust manifold.

Steve

 

When we replaced the head gasket in my '06 HHR it was pretty uneventful until we found the exhaust manifold was cracked.. Finding a replacement was a bit tougher. Some of the exhaust manifolds have a hole drilled in them for a sensor. Mine did not. I ended up with a manifold from a Saturn Vue.

The folks at the junk yard were pretty sure it would fit no problem but told me that if it didn't for some reason I could come back and get one of the three they had on newer HHR's with the extra hole in it and just exchange the one from the Saturn.

One reason I went with the Saturn part is it was already off the car so I didn't have to go out in the junk yard in the cold and snow to remove it.

I'm thinking I could have just put a bolt in the sensor hole and used any of the HHR manifolds. I think they are the same shape just have the extra hole in them.

 

luckily I was able to buy the exact brand new manifold from gmpartsdirect for $60 with the gasket.I'm now thinking about just leaving the exhaust manifold alone after getting under there ,and inspecting it and seeing how tight it is. I'm a big guy and I couldn't even get my arm up to where the exhaust manifold bolts are!

 

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