Cavalier, Sunfire 2001-2005

Exhaust Manifold

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Removal & Installation



2.2L (VIN 4) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Oxygen (O 2 S) sensor electrical connector
     
    Accessory drive belt
     
    Alternator
     
    Radiator inlet pipe
     
    Exhaust pipe-to-exhaust manifold bolts
     
    Oil filler tube
     
    Heater outlet hose assembly-to-exhaust manifold nut
     
    Exhaust manifold
     

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold with new gaskets. Torque the nuts to 115 inch lbs. (13 Nm).
     
    Heater outlet hose assembly-to-exhaust manifold nut. Torque the nut to 18 ft. lbs. (25 Nm).
     
    Oil filler tube
     
    Exhaust pipe-to-exhaust manifold bolts. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    Radiator inlet pipe
     
    Alternator. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Accessory drive belt
     
    O 2 S sensor electrical connector
     
    Negative battery cable
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Start the engine and check for exhaust leaks.
  6.  

2.2L (VIN F) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold heat shield
     
    Oxygen (O 2 S) sensor
     
    Manifold to the exhaust flex decoupler retainers
     

  4.  
  5. Pull down and back on the exhaust pipe in order to disconnect the pipe from the exhaust manifold.

    Exhaust manifold to cylinder head retaining nuts
     
    Exhaust manifold and gasket

    Click image to see an enlarged view

    Fig. Remove the exhaust manifold-2.2L engine

     

  6.  

To install:

  1. Install or connect the following:

    New exhaust manifold gasket
     
    Exhaust manifold and tighten the retainers in sequence to 115 inch lbs. (13 Nm)
     
    New exhaust manifold to flex coupler gasket
     

  2.  
  3. Push the flex coupler into position on the exhaust manifold.

    Retaining nuts and tighten to 22 ft. lbs. (30 Nm)
     
    O 2 S sensor
     
    Exhaust manifold heat shield and tighten the bolts to 18 ft. lbs. (25 Nm)
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Tighten the exhaust manifold retainers in this sequence-2.2L engine

     

  4.  

 
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