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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 95 (ENGINE MECHANICAL - 2.2L)REPAIR INSTRUCTIONSON-VEHICLE REPAIR INSTRUCTIONSENGINE REPLACEMENT (AUTOMATIC TRANSMISSION)INSTALLATION 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 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install J 42451  to the right rear of the cylinder head.
  2. Mount the engine to a stand.
  3. Install the following components:
    • Oil filter cap and filter. Refer to Engine Oil and Oil Filter Replacement .
    • Exhaust manifold studs
    • Exhaust manifold
    • Intake manifold studs
    • Intake manifold
    • Engine mount bracket
    • Engine lift bracket
    • Camshaft cover and seal
    • Fuel rail
    • Engine block heater
    • Water pump
    • Drive belt tensioner
    • Thermostat housing and feed pipe
    • Generator
    • Oil level indicator and tube
    • Crankshaft sensor
    • Camshaft sensor
    • Oil pressure sensor
    • Ignition coil and module assembly
    • Crankshaft balancer
  4. Install an engine hoist to the engine.
  5. Remove the engine from the engine stand.
  6. Install the flywheel. Refer to Engine Flywheel Replacement .
  7. Install the engine to the vehicle.
  8. Align the engine to the transmission.
  9. Install the upper bell housing bolts

    Tighten 

    Tighten the bolts to 90 N.m (66 lb ft).

  10. Install the engine mount. Refer to Engine Mount Replacement .
  11. Remove the engine hoist.
  12. Remove J 42451. 
  13. Raise the vehicle.
  14. Install the lower bell housing bolts.
    Fig 1: Installing Lower Bell Housing Bolts
    G01580559Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the bolts to 90 N.m (66 lb ft).

  15. Install the torque convertor bolts.
    Fig 2: Installing Torque Convertor Bolts
    G01580560Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the torque convertor bolts to 62 N.m (46 lb ft).

  16. Install the starter. Refer to STARTER MOTOR .
  17. Install the brace from the transmission to the engine.
    Fig 3: Installing Brace From Transmission To Engine
    G01580561Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the brace bolts to 72 N.m (53 lb ft).

  18. Connect the front exhaust pipe to the exhaust manifold.
  19. Connect the generator electrical connectors.
  20. Connect the starter electrical connectors.
  21. Install the AC compressor to the engine.
  22. Install the engine drive belt. Refer to Drive Belt Replacement .
  23. Lower the vehicle.
  24. Connect the following electrical connectors:
    • IAC motor
    • TPS
    • Map sensor
    • Crankshaft sensor
    • Camshaft sensor
    • Oil pressure sensor
    • Purge solenoid
    • Ignition coil and module assembly
    • O2 sensor
    • Vehicle speed sensor
    • Engine temperature sensor
  25. Install the radiator inlet hose (3). Refer to RADIATOR HOSE REPLACEMENT - INLET (2.2L - L61) .
  26. Install the hose from the surge tank to the cylinder head (2).
  27. Connect the outlet hose from the surge tank to the radiator (1).
  28. Install the bolt securing the surge tank outlet hose to the intake manifold.
    Fig 4: Identifying Radiator Inlet Hose & Hose From Surge Tank To Cylinder Head
    G01580562Courtesy of GENERAL MOTORS CORP.
  29. Install the radiator outlet hose (1). Refer to RADIATOR HOSE REPLACEMENT - OUTLET (2.2L - L61) .
    Fig 5: Identifying Radiator Outlet Hose
    G01580563Courtesy of GENERAL MOTORS CORP.
  30. Install the inlet (1) and outlet (2) heater hoses. Refer to HEATER HOSE REPLACEMENT - INLET (L61) and HEATER HOSE REPLACEMENT - OUTLET (L61) .
    Fig 6: Identifying Inlet & Outlet Heater Hoses
    G01580564Courtesy of GENERAL MOTORS CORP.
  31. Install the power steering pump.

    Tighten 

    Tighten the power steering pump bolts to 25 N.m (19 lb ft).

    Fig 7: Installing Power Steering Pump
    G01580565Courtesy of GENERAL MOTORS CORP.
  32. Connect the accelerator and cruise control cables.
    Fig 8: Connecting Accelerator & Cruise Control Cables
    G01580566Courtesy of GENERAL MOTORS CORP.
  33. Connect the brake booster hose.
  34. Connect the fuel lines.
  35. Install the air inlet duct and resonator.
  36. Fill the engine with oil.
  37. Connect the negative battery cable.
  38. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM (L61) .
  39. Install the hood. Refer to HOOD REPLACEMENT .
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.