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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 149 (Engine Mechanical - 2.4L (On-Vehicle)) >> Repair Instructions >> Cylinder Head Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Pontiac Sunfire and 2002 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. If removed, install spark plugs.
  2. Install cylinder head gasket.
  3. Install cylinder head.
  4. Install cylinder head bolts.
    1. 4.1. Tighten bolts 1 through 8 to 65 N.m (40 ft lbs).
    2. 4.2. Tighten bolts 9 and 10 to 40 N.m (30 ft lbs).
    3. 4.3. Then turn all bolts an additional 90 degrees in sequence, using the J 36660-A  .
    5. Fig 1: Cylinder Head Bolt Tightening Sequence
    G01777630Courtesy of GENERAL MOTORS CORP.
  5. Connect coolant temperature sensor connector.
  6. Install intake camshaft housing. Refer to Intake Camshaft, Housing & Lifter Replacement 
  7. The exhaust camshaft housing. Refer to Exhaust Camshaft, Housing & Lifter Replacement .
  8. Install the timing chain housing and the timing chain. Refer to Timing Chain Housing Replacement .
  9. Install the fuel rail to the cylinder head. Refer to FUEL RAIL & INJECTORS .
  10. Install the vacuum line to the fuel pressure regulator.
  11. Install the camshaft position sensor connector.

    Important:  When reinstalling the power steering pump apply a 3 mm (0.12 in) bead of GM P/N 12346586 (Canadian P/N 10953472) sealer or the equivalent to the joint at the end of the camshaft housing halves before installation of the power steering pump and the pump face seal.

  12. Install the power steering pump assembly.
  13. Install the electrical connection from the oil pressure switch.
  14. Reinstall any spark plug boot connector assembly that stuck to a spark plug back onto the ignition coil and module assembly.
  15. Locate the ignition coil and the module assembly over the spark plugs and push straight down.
  16. Clean any loose lubricant that is present on the ignition coil and the module assembly to the camshaft housing bolts.
  17. Apply the Pipe Sealant GM P/N 1052080 (Canadian P/N 10953480) or the equivalent onto the ignition coil and the module cover assembly to the camshaft housing bolts. Tighten the bolts to 15 N.m (11 ft lbs) + 30 degrees.
  18. Install the electrical connector to the ignition coil and the module assembly.
  19. Remove the J 28467-360  and the stud-ended generator bolt.
  20. Install the intake manifold.
  21. Connect the coolant temperature sensor connectors.
  22. Connect the upper radiator hose to the coolant outlet.
  23. Connect the following electrical connectors:
    • The MAP sensor
    • The IAT sensor
    • The purge solenoid
    • The fuel injectors
  24. Install the exhaust manifold.
  25. Install the resonator and air cleaner duct.
  26. Fill the cooling system.
  27. Connect the negative battery cable.
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