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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 95 (ENGINE MECHANICAL - 2.2L)REPAIR INSTRUCTIONSOFF-VEHICLE REPAIR INSTRUCTIONSENGINE BLOCK CLEANING AND INSPECTION
2001 Chevrolet Cavalier LS, 2.4 T

Engine Block Cleaning and Inspection

2001 Chevrolet Cavalier LS, 2.4 TSECTION Engine Block Cleaning and Inspection
WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean the sealing material from the gasket mating surfaces.
  2. Clean the engine block and lower crankcase in a cleaning tank with solvent appropriate for aluminum.
  3. Flush the engine block with clean water or steam.
  4. Clean the oil passages.
  5. Clean the blind holes.
  6. Spray the cylinder bores and the machined surfaces with engine oil.
  7. Inspect the threaded holes. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and install thread inserts. Refer to Thread Repair .
    Fig 1: Cleaning Oil Pan Gasket Mating Surface
    G01580663Courtesy of GENERAL MOTORS CORP.

    Important:  Do not attempt to machine the lower crankcase to engine block surfaces.

  8. Use a straight edge and a feeler gage to check the deck surface for flatness. Carefully machine minor irregularities. Replace the block if more than 0.254 mm (0.010 in) must be removed.
  9. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to remove any nicks.
    Fig 2: Checking Deck Surface For Flatness
    G01580664Courtesy of GENERAL MOTORS CORP.
  10. Clean the sealing material from the gasket mating surfaces on the lower crankcase engine block side.
    Fig 3: Cleaning Lower Crankcase Mating Surface (Engine Block Side)
    G01580665Courtesy of GENERAL MOTORS CORP.
  11. Clean the sealing material from the gasket mating surfaces on the lower crankcase oil pan side.
    Fig 4: Cleaning Lower Crankcase Mating Surface (Oil Pan Side)
    G01580666Courtesy of GENERAL MOTORS CORP.
  12. Inspect the mating surfaces of the transmission face.
    NOTE: A broken flywheel may result if the transmission case mating surface is not flat.
  13. Use the following procedure in order to measure the engine block flange runout at the mounting bolt hole bosses:
    1. 13.1. Temporarily install the crankshaft. Measure the crankshaft flange runout.
    2. 13.2. Hold the gage plate flat against the crankshaft flange.
    3. 13.3. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0.
    4. 13.4. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.203 mm (0.008 in).
    5. 13.5. Recheck the crankshaft flange runout if the readings vary more than 0.203 mm (0.008 in).
    Fig 5: Measuring Engine Block Flange Runout At Mounting Bolt Hole Bosses
    G01580667Courtesy of GENERAL MOTORS CORP.
  14. Inspect the crankshaft main bearing bores. Use a bore gage to measure the bearing bore concentricity and alignment.
  15. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.
    Fig 6: Measuring Bearing Bore Concentricity & Alignment
    G01580668Courtesy of GENERAL MOTORS CORP.
  16. Inspect the cylinder bores. Inspect for the following items:
    • Wear
    • Taper
    • Runout
    • Ridging
      Fig 7: Measuring Cylinder Bores
      G01580669Courtesy of GENERAL MOTORS CORP.
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.