Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 225 (ENGINE COOLING SYSTEM - 2.2L (L61))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 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.

Install the surge tank.
NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
Install the surge tank mounting bolt.
Tighten: Tighten the bolt to 10 N.m (89 lb in).
Install the radiator vent hose to the surge tank (3).

Fig 1: Identifying Radiaror Vent & Outlet Hoses
Courtesy of GENERAL MOTORS CORP.
Use the J 38185 in order to reposition the radiator vent hose clamp to the surge tank.
Install the engine vent hose to the surge tank (4).
Use the J 38185 in order to reposition the engine vent hose clamp to the surge tank.
Install the surge tank outlet hose to the surge tank (2).
Use the J 38185 in order to reposition the surge tank outlet hose clamp to the surge tank.
Install the low coolant sensor electrical connector to the retainer.

Fig 2: Identifying Low Coolant Sensor Electrical Connector
Courtesy of GENERAL MOTORS CORP.
Connect the low coolant electrical connector.
Fill the cooling system at the radiator surge tank. Refer to Draining and Filling Cooling System (L61) .

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.