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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 142 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSEXHAUST MANIFOLD REPLACEMENTINSTALLATION PROCEDURE
2001 Chevrolet Cavalier LS, 2.4 T

Installation Procedure

2001 Chevrolet Cavalier LS, 2.4 TSECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install a new exhaust manifold gasket.
  2. Install the exhaust manifold to the cylinder head. See Figure.
    Fig 1: Identifying Exhaust Manifold Bolt Tightening Sequence
    G01581296Courtesy of GENERAL MOTORS CORP.

    Important:  Install the new exhaust nuts.

  3. Install the new exhaust manifold to cylinder head retaining nuts. Follow the tightening sequence.

    Tighten 

    Tighten the nuts to 13 N.m (115 lb in).

  4. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  5. Install a new exhaust manifold to flex coupler gasket (2).
    Fig 2: Connecting Exhaust Pipe To Exhaust Manifold
    G01581297Courtesy of GENERAL MOTORS CORP.
  6. Push the flex coupler into position on the exhaust manifold.

    Important:  Install the new exhaust nuts.

  7. Install the retaining nuts (3) which secure the manifold to the flex decoupler (4).

    Tighten 

    Tighten the nut to 30 N.m (22 lb ft).

  8. Lower the vehicle.
  9. Install the oxygen sensor. Refer to OXYGEN SENSORS .
    Fig 3: Installing Oxygen Sensor
    G01581298Courtesy of GENERAL MOTORS CORP.
  10. Install the exhaust manifold heat shield.
    Fig 4: Installing Exhaust Manifold Heat Shield
    G01581299Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the bolts to 25 N.m (18 ft lbs).

  11. Connect the negative battery cable.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.