LEMON Manuals: Even more car manuals for everyone
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 >> Exhaust Camshaft, Housing & Lifter 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. Install the camshaft housing to the cylinder head with a new gasket. Sealer is unnecessary.
  2. Loosely install one camshaft housing to the cylinder head bolt in order to hold the housing in place.

    Important: 

    • Used lifters must be returned to their original position in the camshaft housing.
    • If the camshaft is being replaced, the lifters must also be replaced.
  3. Install the lifters into the lifter bores.
    NOTE: The camshaft lobes and the journals must be adequately lubricated or serious engine damage will occur upon start up.
  4. Lube the camshaft lobes and the journals with the Camshaft and Lifter Prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
  5. Install the camshaft in the same position as when removed. The timing chain sprocket dowel pin should be straight up and line up with the centerline of the lifter bores.
  6. Install the new camshaft housing to the orange camshaft housing cover seals into the cover. Sealer is unnecessary.
  7. Remove the bolt holding the housing in place.
  8. Apply pipe sealant GM P/N 1052080 (Canadian P/N 10953480) or the equivalent to the camshaft housing and the cover retaining bolt threads.
  9. Install the camshaft housing cover to the camshaft housing.
    Fig 1: Camshaft Housing Cover-To-Camshaft Housing
    G01777588Courtesy of GENERAL MOTORS CORP.
    Fig 2: Camshaft Housing Cover Bolts
    G01777589Courtesy of GENERAL MOTORS CORP.
  10. Use the J 36660-A  Torque Angle Meter, in order to install the bolts.
    • Tighten the camshaft housing to cylinder head bolts to 15 N.m (11 ft lbs) + 90 degrees.
    • Tighten the camshaft housing cover to camshaft housing bolts to 15 N.m (11 ft lbs) + 30 degrees.
  11. Install the timing chain housing to camshaft housing and the timing chain. Refer to Timing Chain Housing Replacement .
  12. Install the exhaust camshaft housing end cover gasket and cover.
  13. Reinstall any spark plugs boot connector assembly that stuck to a spark plug, back onto the ignition coil and module assembly.
  14. Install ignition coil and module assembly.
  15. Connect the negative battery cable.

    Important:  Do not compress the lifter plungers using a vise or other tool. This will cause more air to enter the lifter assembly and will take more time to bleed out once the lifters are installed.

  16. If new lifters have been installed or the lifters bled down while the engine was disassembled excessive lifter noise may be experienced. This is a normal condition and no engine damage is occurring. Use the following procedure in order to purge the air from the lifters:
    1. 16.1. Start the engine and allow to warm up at the idle for 5 minutes.
    2. 16.2. Increase the engine speed to 2,000 RPM until the lifter noise is gone.
    3. 16.3. Return the engine to idle for an additional 5 minutes or perform a road test.
  17. Start the engine and inspect for leaks.
scientia non olet · About LEMON Manuals