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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 237 (Engine Exhaust System) >> Repair Instructions >> Exhaust Manifold Replacement (2.2L (L61)) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  2. Remove the exhaust manifold heat shield.
    Fig 1: Removing & Installing Exhaust Manifold Heat Shield
    GM746055Courtesy of GENERAL MOTORS CORP.
  3. Remove the oxygen sensor. Refer to Heated Oxygen Sensor (HO2S) Replacement (Pre Catalytic Converter) or Heated Oxygen Sensor (HO2S) Replacement (Post Catalytic Converter) in Engine Controls-2.2L (L61).
    Fig 2: Oxygen Sensor & Harness Connector
    GM412121Courtesy of GENERAL MOTORS CORP.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    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.
  5. Remove the pipe to manifold nuts (3).
    Fig 3: Locating Exhaust Manifold To Flex Decoupler Nuts
    GM783174Courtesy of GENERAL MOTORS CORP.
  6. Pull down and back on the exhaust pipe in order to disengage the pipe from the exhaust manifold.
  7. Lower the vehicle.
  8. Remove the exhaust manifold to cylinder head nuts.
  9. Remove the exhaust manifold.
    Fig 4: View Of Exhaust Manifold & Gasket
    GM746061Courtesy of GENERAL MOTORS CORP.
  10. Clean all the sealing surfaces.
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