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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 137 (Engine Exhaust System) >> Repair Instructions >> Exhaust Manifold Replacement (2.4L) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Pontiac Sunfire and 2002 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the Oxygen sensor (O2S) connector.
  2. Raise and support the vehicle.
    Fig 1: Exhaust Manifold Assembly
    G01779375Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not bend the exhaust flex decoupler more than 3 degrees in any direction. Movement of more than 3 degrees will damage the exhaust flex decoupler.
  3. Remove the flex decoupler to exhaust manifold bolts.
    Fig 2: Exhaust Manifold Flex Decoupler
    G01779376Courtesy of GENERAL MOTORS CORP.
  4. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold.
  5. Lower the vehicle.
  6. Remove cruise control module and position aside. Refer to CRUISE CONTROL MODULE .
  7. Remove the exhaust manifold heat shield bolts and shield.
  8. Remove oil level indicator.
  9. Remove the exhaust manifold nuts.
  10. Remove the exhaust manifold and gasket.
  11. Clean all sealing surfaces.
    Fig 3: Exhaust Manifold & Gasket Assembly
    G01779377Courtesy of GENERAL MOTORS CORP.
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