GM Cavalier/Sunfire 1995-2000 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



2.2L Engine

See Figures 1 through 18

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Detach the oxygen sensor wire.
  6.  
  7. Unfasten the exhaust pipe-to-exhaust manifold bolts, then carefully lower the vehicle.
  8.  
  9. Remove the serpentine belt from around the alternator.
  10.  
  11. Remove the alternator-to-bracket bolts, then support the alternator (with the wires attached) out of the way.
  12.  
  13. Remove the alternator bracket.
  14.  
  15. Remove the oil fill tube and disconnect the heater outlet hose assembly nut from the exhaust manifold.
  16.  
  17. Unfasten the retaining nuts, then remove the exhaust manifold from the vehicle. Remove and discard the gasket(s).
  18.  



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Fig. Fig. 1: Exploded view of the exhaust manifold-1995 OHV 2.2L engine



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Fig. Fig. 2: Remove the two manifold-to-exhaust pipe retaining bolts



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Fig. Fig. 3: Remove the wire harness clipe from the alternator bracket



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Fig. Fig. 4: Remove the two upper retaining bolts and ...



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Fig. Fig. 5: ... the two lower retaining bolts and ...



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Fig. Fig. 6: ... remove the alternator bracket



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Fig. Fig. 7: .Remove the oil dipstick bracket retaining bolt and ...



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Fig. Fig. 8: ... remove the dipstick



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Fig. Fig. 9: .Remove the bypase tube bracket retaining nut located under the EGR valve



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Fig. Fig. 10: It may be necessary to remove the hose from the bypase tube to ...



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Fig. Fig. 11: ... remove the tube bracket from the exhaust manifold



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Fig. Fig. 12: .The exhaust manifold is retained by eight nuts



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Fig. Fig. 13: Remove the manifold retaining nute and ...



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Fig. Fig. 14: ... remove the manifold from the engine



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Fig. Fig. 15: The manifold most likely will have one large gasket and ...



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Fig. Fig. 16: ... one gasket around each individual exhaust port



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Fig. Fig. 17: Thoroughly scrape the old gasket material off of the cylinder head and the manifold (if being reused)



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Fig. Fig. 18: A wire brush will be of great aid in cleaning the surface and preparing for a new gasket

To install:
  1. Using a gasket scraper, carefully clean the gasket mounting surfaces.
  2.  
  3. To install, use new gaskete and reverse the removal procedures. Tighten the exhaust manifold-to-cylinder head nute to 10 ft. lbs. (13 Nm).
  4.  
  5. Start the engine and check for exhaust leaks.
  6.  

2.3L and 2.4L Engines

See Figures 19, 20, 21, 22 and 23

  1. Disconnect the negative battery cable
  2.  
  3. Detach the Oxygen (O 2 ) sensor connector.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Unfasten the exhaust manifold brace-to-manifold bolt and the oil pan nuts, if necessary.
  8.  



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Fig. Fig. 19: On the 2.4L engine, remove the bolt and nuts, then remove the brace

  1. Remove the upper heat shield.
  2.  



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Fig. Fig. 20: Unfasten the retaining bolts, then remove the heat shield-2.4L engine shown, 2.3L similar

  1. For the 2.3L engine, remove the manifold-to-exhaust pipe spring loaded nuts.
  2.  

Do NOT bend the exhaust flex decoupler more than necessary to remove it. Excessive movement will damage the flex decoupler.

  1. For the 2.4L engine, remove the manifold-to-exhaust flex decoupler fasteners.
  2.  
  3. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
  4.  
  5. Carefully lower the vehicle.
  6.  
  7. Unfasten the exhaust manifold-to-cylinder head retaining nuts/bolts, then remove the manifold. Remove and discard the gaskets and/or seals. Clean the mating surfaces.
  8.  

To install:
  1. Use gaskets, then position the exhaust manifold. Tighten the retaining nute to 31 ft. lbs. (42 Nm) for the 2.3L engine or to 110 inch lbs. (13 Nm) for the 2.4L engine, in the sequence shown in the accompanying figures.
  2.  



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Fig. Fig. 21: When installing the exhaust manifold, alwaye use a new gasket and tighten the retainers in the correct sequence-2.3L engine



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Fig. Fig. 22: Exhaust manifold installation and fastener tightening sequence-2.4L engine

  1. Raise and safely support the vehicle.
  2.  
  3. Install the heat shield. Tighten the bolts to 10 ft. lbs. (14 Nm).
  4.  
  5. Fasten the exhaust manifold brace-to-manifold bolt and the oil pan nuts. Tighten the bolts to 41 ft. lbs. (56 Nm) and the nute to 18 ft. lbs. (24 Nm).
  6.  
  7. For the 2.3L engine, install the manifold-to-exhaust pipe nuts. Be sure to turn both nuts in evenly to avoid cocking the exhaust pipe and binding the nuts.
  8.  
  9. For the 2.4L engine, install the manifold-to-flex decoupler fasteners. Tighten the bolts to 26 ft. lbs. (35 Nm).
  10.  



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Fig. Fig. 23: Installing the exhaust flex decoupler, which is found on the 2.4L engine

  1. Carefully lower the vehicle.
  2.  
  3. Attach the O 2 connector. Coat the threads of the sensor with a suitable anti-seize compound.
  4.  
  5. Connect the negative battery cable and check for leaks.
  6.  

 
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