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2.3L and 2.4L Engines

Disconnect the negative battery cable




Detach the oxygen sensor connector.




Properly drain the engine coolant into a suitable container.
Remove the heater hose from the thermostat housing for more complete
coolant drain.




Remove upper exhaust manifold heat shield.




Remove the bolt that attaches the exhaust manifold brace to the manifold.




Remove the lower exhaust manifold heat shield.




Break loose the manifold to exhaust pipe spring loaded bolts using a 13mm box wrench.




Raise and safely support the vehicle.

Unfasten the two radiator outlet pipe-to-water pump cover bolts.




Remove the manifold to exhaust pipe bolts from the exhaust pipe flange as follows:





Unscrew either bolt clockwise 4 turns.




Remove the other bolt.




Remove the first bolt.

Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.




Remove the radiator outlet pipe from the oil pan and transaxle.
If equipped with a manual transaxle, remove the exhaust manifold brace.
Leave the lower radiator hose attached and pull down on the outlet pipe
to remove it from the water pump. Leave the radiator outlet pipe hang.




Carefully lower the vehicle.




Unfasten the exhaust manifold-to-cylinder head retaining nuts, then remove the exhaust manifold, seals and gaskets.




For the 2.4L engine, remove the front timing chain cover and the
chain tensioner. For details, please refer to the procedure located
later in this section.




Unfasten the water pump-to-cylinder block bolts. Remove the water
pump-to-timing chain housing nuts. Remove the water pump and cover
mounting bolts and nuts. Remove the water pump and cover as an
assembly, then separate the two pieces.

Thoroughly clean and dry all mounting surfaces, bolts and bolt
holes. Using a new gasket, install the water pump to the cover and
tighten the bolts finger-tight.




Lubricate the splines of the water pump with clean grease and
install the assembly to the engine using new gaskets. Install the
mounting bolts and nuts finger-tight.




Lubricate the radiator outlet pipe O-ring with antifreeze and
slid the pipe onto the water pump cover. Install the bolts finger-tight.




With all gaps closed, tighten the bolts, in the following sequence, to the proper values:





Pump assembly-to-chain housing nuts-19 ft. lbs. (26 Nm).




Pump cover-to-pump assembly-106 inch lbs. (12 Nm).




Cover-to-block, bottom bolt first-19 ft. lbs. (26 Nm).




Radiator outlet pipe assembly-to-pump cover-125 inch lbs. (14 Nm).





Using new gaskets, install the exhaust manifold. Make sure to
following the tightening sequence and torque specifications given in
the exhaust manifold procedure located in this section.




Raise and safely support the vehicle.




Index the exhaust manifold bolts into the exhaust pipe flange.




Connect the exhaust pipe to the manifold. Install the exhaust
pipe flange bolts evenly and gradually to avoid binding. Turn the bolts
in until fully seated.




Connect the radiator outlet pipe to the transaxle and oil pan. Install the exhaust manifold brace, if removed.




On the 2.4L engine, install the timing chain tensioner and front cover.




Install the lower heat shield.




Carefully lower the vehicle.




Fasten the bolt that attaches the exhaust manifold brace to the manifold.




Tighten the manifold-to-exhaust pipe nuts to specification.




Install the upper heat shield.




Attach the oxygen sensor connector.




Fill the radiator with coolant until it comes out the heater hose
outlet at the thermostat housing. Then connect the heater hose. Leave
the radiator cap off.




Connect the negative battery cable, then start the engine. Run
the vehicle until the thermostat opens, fill the radiator and recovery
tank to their proper levels, then turn the engine off.




Once the vehicle has cooled, recheck the coolant level.

2.3L and 2.4L Engines

Disconnect the negative battery cable
Detach the oxygen sensor connector.
Properly drain the engine coolant into a suitable container. Remove the heater hose from the thermostat housing for more complete coolant drain.
Remove upper exhaust manifold heat shield.
Remove the bolt that attaches the exhaust manifold brace to the manifold.
Remove the lower exhaust manifold heat shield.
Break loose the manifold to exhaust pipe spring loaded bolts using a 13mm box wrench.
Raise and safely support the vehicle.

It is necessary to relieve the spring pressure from 1 bolt prior to removing the second bolt. If the spring pressure is not relieved, it will cause the exhaust pipe to twist and bind up the bolt as it is removed.

Unfasten the two radiator outlet pipe-to-water pump cover bolts.
Remove the manifold to exhaust pipe bolts from the exhaust pipe flange as follows:
Unscrew either bolt clockwise 4 turns.
Remove the other bolt.
Remove the first bolt.

On the 2.4L engines, DO NOT rotate the flex coupling more than 4° or damage may occur.

Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
Remove the radiator outlet pipe from the oil pan and transaxle. If equipped with a manual transaxle, remove the exhaust manifold brace. Leave the lower radiator hose attached and pull down on the outlet pipe to remove it from the water pump. Leave the radiator outlet pipe hang.
Carefully lower the vehicle.
Unfasten the exhaust manifold-to-cylinder head retaining nuts, then remove the exhaust manifold, seals and gaskets.
For the 2.4L engine, remove the front timing chain cover and the chain tensioner. For details, please refer to the procedure located later in this section.
Unfasten the water pump-to-cylinder block bolts. Remove the water pump-to-timing chain housing nuts. Remove the water pump and cover mounting bolts and nuts. Remove the water pump and cover as an assembly, then separate the two pieces.

Fig. 9: Water pump and cover mounting-2.3L and 2.4L engines

To install:

Thoroughly clean and dry all mounting surfaces, bolts and bolt holes. Using a new gasket, install the water pump to the cover and tighten the bolts finger-tight.
Lubricate the splines of the water pump with clean grease and install the assembly to the engine using new gaskets. Install the mounting bolts and nuts finger-tight.
Lubricate the radiator outlet pipe O-ring with antifreeze and slid the pipe onto the water pump cover. Install the bolts finger-tight.
With all gaps closed, tighten the bolts, in the following sequence, to the proper values:
Pump assembly-to-chain housing nuts-19 ft. lbs. (26 Nm).
Pump cover-to-pump assembly-106 inch lbs. (12 Nm).
Cover-to-block, bottom bolt first-19 ft. lbs. (26 Nm).
Radiator outlet pipe assembly-to-pump cover-125 inch lbs. (14 Nm).
Using new gaskets, install the exhaust manifold. Make sure to following the tightening sequence and torque specifications given in the exhaust manifold procedure located in this section.
Raise and safely support the vehicle.
Index the exhaust manifold bolts into the exhaust pipe flange.
Connect the exhaust pipe to the manifold. Install the exhaust pipe flange bolts evenly and gradually to avoid binding. Turn the bolts in until fully seated.
Connect the radiator outlet pipe to the transaxle and oil pan. Install the exhaust manifold brace, if removed.
On the 2.4L engine, install the timing chain tensioner and front cover.
Install the lower heat shield.
Carefully lower the vehicle.
Fasten the bolt that attaches the exhaust manifold brace to the manifold.
Tighten the manifold-to-exhaust pipe nuts to specification.
Install the upper heat shield.
Attach the oxygen sensor connector.
Fill the radiator with coolant until it comes out the heater hose outlet at the thermostat housing. Then connect the heater hose. Leave the radiator cap off.
Connect the negative battery cable, then start the engine. Run the vehicle until the thermostat opens, fill the radiator and recovery tank to their proper levels, then turn the engine off.
Once the vehicle has cooled, recheck the coolant level.

This and other details you can find in the 1995-2001-Chevrolet-Cavalier-Repair-Manual

Remember rated this help. Good luck.