2010 HHR 2.2L
I've searched but can't seem to find anything relevant, that's probably my inexperience with the site. I just had a long, swear filled battle getting the old cracked manifold out due to one very stubborn flange nut. I'm putting a new cast iron manifold in with new studs and nuts. At first I screwed all the studs in, put the gasket on and tried to fit the manifold on. It didn't go right on, I can get one side to slide over the studs but the other isn't lining up then. Trying to slide it on evenly doesn't seem to work either. I removed all but the top studs, and it slid on correctly but the outer studs don't line up with the holes.
Is there a trick to getting it on? On a Google search I saw people talking about a spreader being used to stretch out the manifold and make it fit. I'd be afraid I'd break it.

 

If the holes don’t line up, you’ve got a bad casted part or maybe the wrong manifold. Check the part #. Maybe you got a manifold for a 2.4 instead of a 2.2.

Edit : After some looking, it appears the 2.2 and 2.4 use the same exhaust manifold for 2010.

 

If I recall Correctly one or 2 of those studs are really bolts. I think it was 10 and 9. if you only need 1/8 inch putting a wood wedge in the center might do it.
When you tighten the nuts to 10 ft/lb

 

I'll try the wedge thing, might do the trick. The old gasket holes line right up with the new manifold so im pretty sure its not a bad part problem.

 

After looking really well with a mirror the end bolt holes aren't even close to right. Firemangeorge is right I think. Returning the part to rockauto and buying genuine gm manifold and gasket.
Thanks for taking the time you guys.
Cheers
Zack