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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 149 (ENGINE MECHANICAL - 2.4L (ON-VEHICLE))REPAIR INSTRUCTIONSINTAKE 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 2002 Pontiac Sunfire and 2002 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.

Important:  The engine and the manifold should be at ambient temperature when assembled. Do not attempt to install a cold manifold on a hot engine.

  1. Install the intake manifold and the gasket. If the gasket is damaged, install a new one with the stamped numbers facing towards the manifold surface.
  2. Install the intake manifold nut and bolts. Tighten the nuts and bolts in sequence (1,2,3,4,5,6 and 7) to 24 N.m (18 ft lbs).
    3. Fig 1: Intake Manifold Tightening Sequence
    G01777571Courtesy of GENERAL MOTORS CORP.
  3. Install wiring harness to retainer on bottom of intake.
  4. Install brake booster vacuum line to throttle body.
  5. Install the stud ended generator mount bolt.
  6. Install the accelerator control cable bracket.
  7. Connect the vacuum hoses to the fuel regulator and to the EVAP canister purge solenoid.

    Important:  If the IAT sensor is removed, apply sealant GM P/N 1052080 (Canadian P/N 10953480) or equivalent to its threads before installation.

  8. Connect the following electrical connections:
    • MAP sensor
    • IAT sensor
    • EVAP canister purge solenoid
    • Fuel injector harness
  9. Install the air cleaner resonator and duct.
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.