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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 134 (ENGINE MECHANICAL - 2.2L (L61) (UNIT REPAIR))REPAIR INSTRUCTIONSPISTON, CONNECTING ROD & BEARING INSTALLATION
2001 Chevrolet Cavalier LS, 2.4 T

Piston, Connecting Rod & Bearing Installation

2001 Chevrolet Cavalier LS, 2.4 TSECTION Piston, Connecting Rod & Bearing Installation
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.

Tools Required 

  • J 8037  Piston Ring Compressor
  • J 36660-A  Torque Angle Meter
  • J-43966-1  Connecting Rod Guides
  1. Install the connecting rod bearings. Use the proper size bearings.
    1. 1.1. Install the bearing inserts into the connecting rod and the connecting rod cap.
    2. 1.2. Lubricate the connecting rod bearings with engine oil.
  2. Install the J-43966-1  into the connecting rod bolt holes This protects the crankshaft journal during piston and connecting rod installation.
  3. Install the piston and the connecting rod to the correct bore.
    1. 3.1. Stagger each piston ring end gap equally around the piston.
    2. 3.2. Lubricate the piston and the piston rings with engine oil.
    3. 3.3. Install J 8037  over the piston. Do not disturb the piston ring end gap location.
    4. 3.4. The piston must be installed so that the mark on the top of the piston faces the front of the engine.
    5. 3.5. Place the piston in its matching bore.
    6. 3.6. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place.
    7. 3.7. Hold the J 8037  against the engine block until all the rings have entered the cylinder bore.
    8. 3.8. Remove the connecting rod guides from the connecting rod bolt holes.
    Fig 1: Connecting Rod Guides
    G01777443Courtesy of GENERAL MOTORS CORP.

    Important:  Ensure that the connecting rod cap is properly oriented on the connecting rod.

  4. Install the connecting rod cap.
    5. Fig 2: Connecting Rod Cap
    G01777444Courtesy of GENERAL MOTORS CORP.
  5. Install the connecting rod bolts. Always use new bolts.

    Tighten 

    Tighten the connecting rod bolt nuts to 25 N.m (18 lb ft), then rotate 100 degrees using the J 36660-A. 

  6. Install the remaining connecting rods and piston assemblies.
  7. Measure the connecting rod side clearance with a feeler gauge.

    The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in).

    Fig 3: Measuring Connecting Rod Side Clearance With A Feeler Gauge
    G01777445Courtesy of GENERAL MOTORS CORP.
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.