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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 >> Intake 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 on camshaft housing to the cylinder head bolt in order to hold the housing in place.

    Important:  Used lifters must be returned to the original position in the camshaft housing. If the camshaft is being replaced, the lifters actuated by the camshaft must also be replaced.

  3. Install the lifters into the lifter bores.
  4. 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.
  5. Install the new camshaft housing to the green colored camshaft housing cover seals and into the cover. Sealant is unnecessary.
  6. Remove the bolt holding the housing in place.
  7. Apply the pipe sealant GM P/N 1052080 (Canadian P/N 10953480) or the equivalent to the camshaft housing and the cover retaining bolt threads.
  8. Install the camshaft housing cover to the camshaft housing.

    Important:  The top intake camshaft housing bolts are tightened to a different specification that the other camshaft housing bolts.

  9. Using the J 36660-A  Torque Angle Meter: Tighten the camshaft housing to cylinder head bolts to 15 N.m (11 ft lbs) + 90 degrees.
  10. Tighten the camshaft housing cover to camshaft housing bolts to 15 N.m (11 ft lbs) + 30 degrees.
  11. Install the timing chain housing and the timing chain.
  12. Install the camshaft position sensor connector.
  13. Install electrical to oil pressure sensor.

    Important:  When reinstalling the power steering pump, apply a 3 mm bead of GM P/N 12346286 (Canadian P/N 10953472) sealer or the equivalent to the joint at the end of the camshaft housing halves before the installation of the power steering pump and the pump face seal.

  14. Install the power steering pump assembly.
  15. Install ignition coil and module assembly.

    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 to purge air from the lifters:
    1. 15.1. Start the engine and allow the engine to warm up at idle for 5 minutes.
    2. 15.2. Increase the engine speed to 2,000 RPM until the lifter noise is gone.
    3. 15.3. Return the engine to idle for an additional 5 minutes or perform a road test.
  17. Connect the negative battery cable.
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