Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 142 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSINTERMEDIATE PIPE REPLACEMENTREMOVAL PROCEDURE

2001 Chevrolet Cavalier LS, 2.4 T

Removal Procedure

2001 Chevrolet Cavalier LS, 2.4 TSECTION Removal 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.

NOTE: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.

Important: A service muffler will be needed when replacing the intermediate pipe on an originally equipped, welded system.

Raise the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
Support the three way catalytic converter.
Cut the intermediate pipe (1) at the muffler (2).

Fig 1: Cutting Intermediate Pipe At Muffler
Courtesy of GENERAL MOTORS CORP.
Remove the intermediate pipe bolts at catalytic converter.

Fig 2: Removing/Installing Intermediate Pipe Bolts At Catalytic Converter
Courtesy of GENERAL MOTORS CORP.
Remove the intermediate pipe from the hanger.

Fig 3: Removing Intermediate Pipe From Hanger
Courtesy of GENERAL MOTORS CORP.
Remove the intermediate pipe.
Remove the three way catalytic converter seals.

Fig 4: Removing/Installing Three Way Catalytic Converter Seals
Courtesy of GENERAL MOTORS CORP.
Clean the flange surface.

RENDER: 1.0x

NO RELATED

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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.