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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 162 (FRONT SUSPENSION SYSTEM)REPAIR INSTRUCTIONSFRONT SUSPENSION CROSSMEMBER 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 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise the crossmember to the vehicle.
    1. Align the crossmember dowel pins to the frame rails.
    2. Align the engine mount studs.
    NOTE: Refer to FASTENER NOTICE .
  2. Install new crossmember mounting nuts.
    Fig 1: Installing Crossmember Mounting Nuts
    G01419356Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the new crossmember mounting nuts to 110 N.m (81 lb ft).

  3. Install the engine mount lower nuts. Refer to one of the following procedures:
  4. Fasten the wheel speed sensor wiring harness retaining clips to the crossmember.
    Fig 2: Installing Wheel Speed Sensor Wiring Harness Retaining Clips To Crossmember
    G01419357Courtesy of GENERAL MOTORS CORP.
  5. Fasten the brake pipe to the retaining clips on the crossmember.
  6. Connect the electrical harness to the clips on the crossmember.
    Fig 3: Connecting Electrical Harness To Clips On Crossmember
    G01419358Courtesy of GENERAL MOTORS CORP.
  7. Connect the brake pipe to the clips on the crossmember.
  8. Install the transverse spring with the J 33432-A  connected, to the crossmember. Refer to FRONT TRANSVERSE SPRING REPLACEMENT  .
    Fig 4: Installing Transverse Spring
    G01419359Courtesy of GENERAL MOTORS CORP.
  9. Install the lower control arm to the crossmember. Refer to LOWER CONTROL ARM REPLACEMENT  .
    Fig 5: Installing Lower Control Arm To Crossmember
    G01419360Courtesy of GENERAL MOTORS CORP.
  10. Install the shock absorbers to the lower control arms.
    Fig 6: Installing Shock Absorbers To Lower Control Arms
    G01419361Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the shock absorber lower mounting nuts to 28 N.m (21 lb ft).

  11. Install the power steering gear to the crossmember.
    Fig 7: Installing Power Steering Gear To Crossmember
    G01419362Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the power steering gear mounting bolts to 100 N.m (74 lb ft).

  12. Install the bolts to the brake pressure modulator valve bracket. Refer to BRAKE PRESSURE MODULATOR VALVE (BPMV) BRACKET REPLACEMENT in Antilock Brake System.
  13. Connect the intermediate shaft to the steering gear. Refer to INTERMEDIATE STEERING SHAFT REPLACEMENT in Steering Wheel and Column.
  14. Install the steering linkage outer tie rod ends to the steering knuckles. Refer to TIE ROD END REPLACEMENT - OUTER in Power Steering Systems.
  15. Connect the ESC sensor links to the upper control arm, if equipped.
    Fig 8: Connecting ESC Sensor Links
    G01419363Courtesy of GENERAL MOTORS CORP.
  16. Connect the shock absorber solenoid electrical connector, if equipped.
    Fig 9: Connecting Shock Absorber Solenoid Electrical Connector
    G01419364Courtesy of GENERAL MOTORS CORP.
  17. Install the stabilizer shaft to the vehicle. Refer to STABILIZER SHAFT REPLACEMENT  .
  18. Install the tire and wheel assemblies. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  19. Lower the vehicle.
  20. Remove J 41803  and J 28467-B  from the engine.
  21. Install the generator. Refer to GENERATOR in Engine Electrical.
  22. Install the washer pump/reservoir. Refer to WASHER SOLVENT CONTAINER REPLACEMENT in Wipers/Washer Systems.
  23. Install the engine coolant temperature switch electrical connector.
    Fig 10: Installing Engine Coolant Temperature Switch Electrical Connector
    G01419365Courtesy of GENERAL MOTORS CORP.
  24. Install the front headlamp electrical connector.
  25. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
  26. Perform a vehicle front end alignment. Refer to MEASURING WHEEL ALIGNMENT in Wheel Alignment.
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.