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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 169 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSSURGE TANK 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.

Important:  Lubricate the inside diameters of the hoses with clean coolant prior to installation.

  1. Install the surge tank.
  2. Install the heater outlet hose to the surge tank.
  3. Reposition the heater outlet hose clamp to the surge tank.
    Fig 1: Installing Heater Outlet Hose To Surge Tank
    G01971754Courtesy of GENERAL MOTORS CORP.
  4. Install the surge tank inlet (1) hose to the surge tank.
  5. Reposition the surge tank inlet hose clamp.
  6. Install the surge tank outlet hose to the surge tank.
  7. Reposition the surge tank outlet hose clamp (2) to the surge tank.
    Fig 2: Installing Surge Tank Inlet Hose & Outlet Hose To Surge Tank
    G01971755Courtesy of GENERAL MOTORS CORP.

    Important:  When installing the surge tank ensure that the front stud is fully seated in the slot.

  8. Install the surge tank onto the studs.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  9. Install the surge tank nuts.
  10. Tighten the nuts.
    1. 10.1. Bottom
    2. 10.2. Top rear
    3. 10.3. Top front

      Tighten 

      Tighten the radiator surge tank nuts to 10 N.m (89 lb in).

  11. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
    Fig 3: Upper Surge Tank
    G01971756Courtesy 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.