GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Exhaust Manifold

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REMOVAL & INSTALLATION



1.8L, 2.0L and 2.2L OHV Engines

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Detach the oxygen sensor wire.
  4.  
  5. Remove the serpentine belt or alternator drive belt.
  6.  
  7. Remove the alternator-to-bracket bolts, then support the alternator (with the wires attached) out of the way.
  8.  
  9. For 1982-84 vehicles equipped with the A.I.R. or pulse air system, disconnect the pipes and hoses.
  10.  
  11. Raise and support the vehicle safely.
  12.  
  13. Unfasten the exhaust pipe-to-exhaust manifold bolts, then carefully lower the vehicle.
  14.  
  15. If necessary for access to remove the manifold, remove the oil fill tube and disconnect the heater outlet hose assembly nut from the exhaust manifold.
  16.  
  17. Remove the exhaust manifold-to-cylinder head bolts.
  18.  
  19. Detach the exhaust manifold from the exhaust pipe flange.
  20.  
  21. Unfasten the retaining nuts, then remove the exhaust manifold from the vehicle. Remove and discard the gasket(s).
  22.  



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Fig. Fig. 1: Exploded view of the exhaust manifold mounting - OHV 1.8L engine shown



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Fig. Fig. 2: When installing the exhaust manifold, always use a new gasket - OHV 2.2L engine shown

To install:
  1. Using a gasket scraper, carefully clean the gasket mounting surfaces.
  2.  
  3. To install, use new gaskets and reverse the removal procedures. Tighten the exhaust manifold-to-cylinder head nuts to 3-12 ft. lbs. (4-16 Nm) and the bolts to 6-13 ft. lbs. (8-18 Nm).
  4.  
  5. Start the engine and check for exhaust leaks.
  6.  

1.8L and 2.0L OHC Engines
EXCEPT TURBOCHARGER

See Figure 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Tag and disconnect the spark plug wires from the spark plugs, then remove the retainers.
  6.  
  7. Remove the oil dipstick tube and the breather.
  8.  
  9. Detach the Oxygen (O 2 ) sensor electrical connector.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove the exhaust pipe from the manifold, then support the pipe.
  14.  
  15. Unfasten the retaining nuts, then remove the exhaust manifold by lowering it from the bottom of the vehicle. Remove and discard the gasket. Clean the exhaust manifold and cylinder head gasket mating surfaces.
  16.  



Click image to see an enlarged view

Fig. Fig. 3: When installing the exhaust manifold, tighten runners #2 and #3 before #1 and #4 - except 2.0L Turbo engines

To install:
  1. Use a new gasket, position the exhaust manifold, then secure using the retaining nuts. Tighten the nuts to 16 ft. lbs. (22 Nm), in the sequence shown in the accompanying figure.
  2.  
  3. Connect the exhaust pipe to the manifold. Tighten the retaining nuts to 16-19 ft. lbs. (22-26 Nm).
  4.  
  5. Carefully lower the vehicle.
  6.  
  7. Attach the (O 2 ) sensor electrical connector.
  8.  
  9. Install the breather and the oil dipstick tube.
  10.  
  11. Connect the spark plugs as tagged during remove, then install the retainers.
  12.  
  13. Install the air cleaner assembly.
  14.  
  15. Connect the negative battery cable.
  16.  

TURBOCHARGER

See Figures 4 and 5

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the turbo induction tube.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: Removing the turbo induction tube is simply a matter of unfastening the clamps, then removing the tube from the engine

  1. Label and detach the spark plug wires.
  2.  
  3. Remove the turbocharger. For details, please refer to the procedure located later in this section.
  4.  
  5. If applicable, detach the wiring from the oxygen sensor.
  6.  
  7. Unfasten the bolts and nuts retaining the exhaust manifold to the block and exhaust pipe, then remove the manifold. Remove and discard the gasket.
  8.  

To install:

Before installing a new gasket on the 1.8L MFI Turbo engine (code J), check for the location of the stamped part number on the surface. This gasket should be installed with this number toward the manifold. The gasket appears to be the same in either direction but it is not. Installing the gasket backwards will result in a leak.

  1. Install the exhaust manifold with a new gasket. Install the retainers, then tighten (in the sequence shown in the accompanying figure) the studs to 20 ft. lbs. (27 Nm,) and the nuts to 16 ft. lbs. (22 Nm).
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Exhaust manifold mounting and retainer tightening sequence - 2.0L engine

  1. Connect the exhaust pipe to the exhaust manifold and tighten the nuts to 19 ft. lbs. (25 Nm).
  2.  
  3. Attach the wire to the oxygen sensor, if applicable.
  4.  
  5. Install the turbocharger. For details, please refer to the procedure located later in this section.
  6.  
  7. Connect the spark plug wires as tagged during removal.
  8.  
  9. Install the turbo induction tube.
  10.  
  11. Connect the negative battery cable.
  12.  

2.8L and 3.1L Engines
1985-86 VEHICLES (LEFT SIDE)

See Figure 6

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the air flow sensor.
  6.  
  7. Unfasten, then remove the engine heat shield.
  8.  
  9. Detach the crossover pipe at the exhaust manifold.
  10.  
  11. Unfasten the exhaust manifold bolts, then remove the manifold.
  12.  
  13. Clean the surfaces of the cylinder head and manifold.
  14.  

To install:
  1. Place the manifold into position, then loosely install the manifold bolts just enough to hold the manifold.
  2.  
  3. Install the exhaust crossover pipe to the manifold.
  4.  
  5. Tighten the manifold bolts evenly to 25 ft. lbs. (34 Nm).
  6.  
  7. Install the heat shield and the mass flow sensor.
  8.  
  9. Install the air cleaner and the negative battery cable.
  10.  



Click image to see an enlarged view

Fig. Fig. 6: Exhaust manifold removal and installation - 1985-86 2.8L engines

1985-86 VEHICLES (RIGHT SIDE)

See Figure 6

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the air flow sensor. Remove the heat shield.
  6.  
  7. Disconnect the crossover pipe at the manifold.
  8.  
  9. Detach the accelerator and Throttle Valve (TV) cable at the throttle lever and the plenum. Move aside to gain working clearance.
  10.  
  11. Disconnect the power steering line at the power steering pump.
  12.  
  13. Remove the EGR valve assembly.
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. Disconnect the exhaust pipe at the exhaust manifold.
  18.  
  19. Carefully lower the vehicle.
  20.  
  21. Unfasten the exhaust manifold bolts, then remove the manifold.
  22.  
  23. Clean the surfaces of the cylinder head and manifold.
  24.  

To install:
  1. Place the manifold into position and loosely install the retaining bolts just enough to hold the manifold.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Install the exhaust pipe at the manifold.
  6.  
  7. Carefully lower the vehicle.
  8.  
  9. Tighten the manifold bolts, evenly, to 25 ft. lbs. (34 Nm).
  10.  
  11. Install the EGR valve and related parts.
  12.  
  13. Connect the power steering line at the power steering pump.
  14.  
  15. Attach the accelerator and throttle valve cable at the throttle lever and the plenum.
  16.  
  17. Connect the crossover pipe at the manifold.
  18.  
  19. Install the heat shield and the mass air flow sensor.
  20.  
  21. Install the air cleaner assembly and connect the negative battery cable.
  22.  

1987-93 VEHICLES (LEFT SIDE)

See Figures 7, 8 and 9

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the air cleaner inlet hose and the mass air flow sensor, on models so equipped.
  6.  
  7. Properly drain the coolant, then remove the coolant by-pass pipe
  8.  
  9. Remove the heat shield.
  10.  
  11. Disconnect the exhaust crossover pipe at the manifold.
  12.  
  13. Unfasten the exhaust manifold bolts and remove the exhaust manifold or manifold/crossover assembly.
  14.  

To install:
  1. Clean the surfaces of the cylinder head and manifold.
  2.  
  3. Using a new gasket, place the manifold into position and loosely install the manifold bolts.
  4.  
  5. Attach the exhaust crossover pipe to the manifold.
  6.  
  7. Tighten the exhaust manifold bolts evenly to 18-21 ft. lbs. (24-28 Nm).
  8.  
  9. Install the heat shield. Tighten the nuts to 89 inch lbs. (10 Nm).
  10.  
  11. Connect the coolant pipe.
  12.  
  13. Install the air cleaner inlet hose and the air cleaner assembly
  14.  
  15. Fill the cooling system.
  16.  
  17. Connect the negative battery cable.
  18.  



Click image to see an enlarged view

Fig. Fig. 7: Exhaust manifold removal and installation - 1987 2.8L engine shown



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Fig. Fig. 8: Removing the exhaust manifold - 1993 3.1L engine shown



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Fig. Fig. 9: The exhaust crossover pipe on the 3.1L engines is retained by two nuts

1987-93 VEHICLES (RIGHT SIDE)

See Figures 7, 8 and 9

  1. Disconnect the negative battery cable.
  2.  
  3. For 1993 vehicles, remove the air cleaner assembly.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the heat shield.
  8.  
  9. Disconnect the exhaust pipe at the crossover.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. Remove the EGR valve or pipe.
  14.  
  15. Disconnect the oxygen sensor wire.
  16.  
  17. Unfasten the exhaust manifold bolts, then remove the manifold.
  18.  
  19. Clean the mating surfaces of the cylinder head and manifold. Discard the gasket.
  20.  

To install:
  1. Use a new manifold gasket, place the manifold into position and loosely install the manifold bolts.
  2.  
  3. Install the crossover at the manifold.
  4.  
  5. Tighten the manifold bolts evenly to 21-25 ft. lbs. (28-34 Nm).
  6.  
  7. Install the EGR valve or pipe and connect the oxygen sensor wire.
  8.  
  9. Raise and support the vehicle safely.
  10.  
  11. Connect the exhaust pipe to the crossover.
  12.  
  13. Install the engine heat shield.
  14.  
  15. Carefully lower the vehicle.
  16.  
  17. Connect the negative battery cable.
  18.  

1994 VEHICLES (LEFT SIDE)

See Figure 10

On these 3.1L engines, and Idle Learn procedure must be performed which requires the use of a scan tool.

  1. Disconnect the negative, then the positive battery cables.
  2.  
  3. Remove the battery.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Unfasten the lower cooling fan bolt and detach the electrical connector.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. Remove the cooling fan assembly.
  14.  
  15. Disconnect the exhaust crossover pipe.
  16.  
  17. Tag and disconnect the left side spark plug wires from the spark plugs and position aside.
  18.  
  19. Remove the exhaust manifold heat shield.
  20.  
  21. Unfasten the retaining bolts, then remove the exhaust manifold.
  22.  
  23. Clean the mating surfaces of the cylinder head and manifold. Discard the gasket.
  24.  

To install:
  1. Use a new manifold gasket, place the manifold into position and loosely install the manifold bolts.
  2.  
  3. Tighten the exhaust manifold bolts to 21 ft. lbs. (28 Nm).
  4.  
  5. Install the exhaust manifold heat shield. Tighten the retaining nuts to 89 inch lbs. (10 Nm).
  6.  
  7. Attach the spark plug wires to the plugs, as tagged during removal.
  8.  
  9. Fasten the exhaust crossover pipe to the manifolds.
  10.  
  11. Install the cooling fan, and secure with the upper retaining bolts.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Install the lower cooling fan assembly bolt and attach the electrical connector.
  16.  
  17. Carefully lower the vehicle.
  18.  
  19. Install the air cleaner assembly.
  20.  
  21. Install the battery, then connect the positive, then the negative battery cables.
  22.  

On the 3.1L engine, a Tech 1® scan tool is needed to perform the "Idle Learn" procedure.

  1. For the 3.1L engine perform the following "Idle Learn" procedure;
    1. Install a Tech 1® scan tool.
    2.  
    3. Turn the ignition to the ON position, engine not running.
    4.  
    5. Select IAC SYSTEM , then IDLE LEARN in the MISC TEST mode.
    6.  
    7. Place the transaxle in park or neutral, as applicable.
    8.  
    9. Proceed with idle learn as directed by the scan tool.

      Click image to see an enlarged view

      Fig. Fig. 10: View of the exhaust manifold mounting - 1994 3.1L engine shown

    10.  

  2.  

1994 VEHICLES (RIGHT SIDE)

See Figure 10

On these 3.1L engines, and Idle Learn procedure must be performed which requires the use of a scan tool.

  1. Disconnect the negative, then the positive battery cables.
  2.  
  3. Remove the battery.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Disconnect the exhaust crossover pipe from the manifolds.
  8.  
  9. Detach the Oxygen sensor electrical connector.
  10.  
  11. Disconnect the EGR pipe from the exhaust manifold.
  12.  
  13. For vehicles equipped with an automatic transaxle, remove the transaxle fluid level indicator and fill tube.
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. For vehicles equipped with an automatic transaxle, remove the suspension support crossmember brace.
  18.  
  19. For vehicles equipped with a manual transaxle, remove the heat shield. If equipped with an automatic transaxle, remove the nut but do not remove the heat shield from the vehicle at this time.
  20.  
  21. Disconnect the exhaust pipe from the exhaust manifold.
  22.  
  23. If equipped with an automatic transaxle, remove the exhaust manifold extension pipe.
  24.  
  25. Unfasten the retaining bolts, then remove the exhaust manifold from the vehicle. If equipped with an automatic transaxle, remove the heat shield with the exhaust manifold.
  26.  
  27. Clean the mating surfaces of the cylinder head and manifold. Discard the gasket.
  28.  

To install:
  1. Use a new manifold gasket, place the manifold (and heat shield, if automatic) into position and loosely install the manifold bolts.
  2.  
  3. Tighten the exhaust manifold bolts to 21 ft. lbs. (28 Nm).
  4.  
  5. If equipped with an automatic transaxle, install the exhaust manifold extension pipe.
  6.  
  7. If applicable, install the exhaust manifold heat shield, then tighten the nut to 89 inch lbs. (10 Nm).
  8.  
  9. Attach the exhaust pipe to the manifold.
  10.  
  11. If equipped with an automatic transaxle, install the suspension support crossmember brace.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. If equipped with an automatic transaxle, install the transaxle fluid level indicator and fill tube.
  16.  
  17. Attach the EGR pipe to the exhaust manifold.
  18.  
  19. Engage the Oxygen sensor connector.
  20.  
  21. Fasten the exhaust crossover to the manifolds.
  22.  
  23. Install the air cleaner assembly.
  24.  
  25. Install the battery, then connect the positive, then negative battery cables.
  26.  

On the 3.1L engine, a Tech 1® scan tool is needed to perform the "Idle Learn" procedure.

  1. For the 3.1L engine perform the following "Idle Learn" procedure;
    1. Install a Tech 1® scan tool.
    2.  
    3. Turn the ignition to the ON position, engine not running.
    4.  
    5. Select IAC SYSTEM , then IDLE LEARN in the MISC TEST mode.
    6.  
    7. Place the transaxle in park or neutral, as applicable.
    8.  
    9. Proceed with idle learn as directed by the scan tool.
    10.  

  2.  

 
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