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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 95 (ENGINE MECHANICAL - 2.2L)REPAIR INSTRUCTIONSOFF-VEHICLE REPAIR INSTRUCTIONSINTAKE MANIFOLD INSTALLATION
2001 Chevrolet Cavalier LS, 2.4 T

Intake Manifold Installation

2001 Chevrolet Cavalier LS, 2.4 TSECTION Intake Manifold Installation
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. Install the intake manifold studs in the manifold face.

    Tighten 

    Tighten the intake manifold studs to 5 N.m (44 lb in).

    Fig 1: Installing Intake Manifold Studs
    G01580835Courtesy of GENERAL MOTORS CORP.
  2. Install a new intake manifold gasket on the intake manifold.
  3. Install the intake manifold.
  4. Install the intake manifold bolts and nuts. Follow the tightening sequence.

    Tighten 

    Tighten the bolts and nuts to 10 N.m (89 lb in).

    Fig 2: Installing Intake Manifold
    G01580836Courtesy of GENERAL MOTORS CORP.
  5. Lubricate the fuel injector tip insulators with engine oil.
  6. Install new fuel injector tip insulators.
  7. Lubricate the fuel injector oil rings with engine oil.
  8. Install the fuel rail assembly.
  9. Install the fuel rail stud.

    Tighten 

    Tighten the stud to 10 N.m (89 lb in).

    Fig 3: Installing Fuel Rail
    G01580837Courtesy of GENERAL MOTORS CORP.
  10. Install a new throttle body gasket.
  11. Install the throttle body and the accelerator control cable bracket.

    Tighten 

    Tighten the bolts and nuts to 10 N.m (89 lb in).

    Fig 4: Installing Throttle Body & Accelerator Control Cable Bracket
    G01580838Courtesy of GENERAL MOTORS CORP.

    Important:  Ensure that the rear metal tab of the EVAP emission canister valve is resting on the power steering pump metal body.

  12. Install the EVAP emission canister valve (2).

    Tighten 

    Tighten the EVAP canister valve to 22 N.m (16 lb ft).

  13. Install the EVAP emission canister valve tube (1).
    Fig 5: Installing EVAP Emission Canister Valve
    G01580839Courtesy 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.