Engine Mechanical - 2.4l 4-cylinder Chevrolet Cavalier III

ENGINE IDENTIFICATION

Note. For repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES article in GENERAL INFORMATION.

Vehicle Identification Number (VIN) is stamped on a metal tab, attached to top left end of instrument panel, near the windshield. Engine can also be identified by an engine code (3rd character) stamped on left side of cylinder block. (Scheme 1) See the ENGINE IDENTIFICATION CODES table.

ENGINE IDENTIFICATION CODES

Scheme 1

VALVE CLEARANCE ADJUSTMENT

Engine is equipped with non-adjustable hydraulic valve lifters.

TROUBLE SHOOTING

Note. To trouble shoot mechanical engine components, see ENGINE MECHANICAL in BASIC TROUBLE SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

FUEL PRESSURE RELEASE

Disconnect negative battery cable. Loosen fuel filler cap. Install Fuel Pressure Gauge (J-34730-1) on fuel pressure connector of fuel rail. Wrap shop towel around pressure connection when installing fuel pressure gauge to absorb fuel leakage. Install gauge bleed hose into container. Open bleed valve to bleed fuel pressure.

COOLING SYSTEM BLEEDING

1. Fill radiator and surge tank to base of filler neck. Install pressure cap on surge tank. Block drive wheels and firmly apply parking brake. Shift automatic transaxle to Park or manual transaxle to Neutral. Start engine. Run until upper radiator hose is hot. Stop engine.
2. Observe coolant level in surge tank or radiator. If not above FULL mark, allow engine to cool and then remove surge tank cap. Add coolant. If low coolant light lights after servicing, remove surge tank cap and add coolant to bring level to COLD FULL mark when system is cold.

Removal (Manual Transmission)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__fuel-pressure-release) . Disconnect negative battery cable. Drain cooling system. Discharge air conditioning system (if equipped) using approved refrigerant recovery/recycling equipment.
2. Remove air cleaner assembly. Disconnect shift cables at shift control. Remove shift cables from bracket and remove bracket. Disconnect back-up light switch. Disconnect vehicle speed sensor, engine control harness and vacuum lines. Disconnect fuel line quick disconnects. Remove radiator hoses. Disconnect heater hoses from heater core.
3. Disconnect clutch actuator (slave cylinder) hydraulic line. Remove EVAP solenoid. Remove power steering pump bolts and pump (leave hoses connected), and set aside. Remove starter (leave wires connected), and set aside. Disconnect surge tank bypass hose from engine. Disconnect cruise and accelerator cables from throttle body. Remove and position cruise control module aside. Tie radiator to hood latch panel with mechanics wire.
4. Raise and support vehicle. Safety strap front of vehicle to hoist. Drain transaxle. Drain engine oil and remove oil filter. Remove front splash shields. Remove front closeout panel fasteners and panel. Remove lower radiator support. Remove right front brake hose. Remove retaining nut from BPMV at mounting bracket.
5. Disconnect wheel speed sensor, and disconnect harness from control arm retainers. Remove wheel speed sensor harness from frame retainers, and position aside. Remove wheel axle shafts. Disconnect ball joints and outer tie rod ends from control arms. Disconnect catalytic converter from exhaust manifold. Remove A/C compressor hose from A/C compressor.
6. Remove bolt from power steering pressure line retainer. Lower vehicle until front suspension crossmember rests on support table. Position a 3 inch block of wood between front of oil pan and crossmember. Remove front engine mount to bracket bolts. Remove front suspension crossmember retaining bolts. With help from an assistant, carefully raise vehicle off of engine/transaxle assembly. Install engine hoist to engine/transmission assembly.
7. Remove front and rear transmission mount through-bolt. Remove transmission mount lower nuts. Raise vehicle slowly from engine and transaxle assembly. Separate engine from tranaxle (note bolt location for reassembly reference). Remove clutch drive and clutch driven plate. Remove flywheel. Mount engine on a suitable engine stand.

Installation (Manual Transmission)

1. Assemble engine to transaxle, ensuring bolts are in correct locations. Lower vehicle until transaxle mount is aligned. Install transaxle mount bolt.
2. Install suspension support, crossmember and stabilizer shaft assembly. Tighten suspension support rear bolts, center bolts and then front bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__torque-specifications) . Connect ball joints. Install engine mount strut. To complete installation, reverse removal procedure. Evacuate and charge air conditioning system. Fill cooling system and crankcase.

Removal (Automatic Transmission)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__fuel-pressure-release) . Disconnect negative battery cable. Drain cooling system and engine oil. Remove fuel rail assembly, air intake duct from air cleaner, ignition coil and module assembly. Disconnect control cables, coolant hoses, electrical connectors, vacuum hoses, and fuel lines as necessary.
2. Unbolt power steering pump, and secure aside. Remove air intake duct bracket. Remove cruise control assembly, and set aside. Install J 28467-360 engine support fixture. Remove fan belt and engine mount assembly. Raise engine using support fixture, then remove engine mount bracket.
3. Raise and support vehicle. Remove front wheels and right splash shield. Remove crankshaft balancer. Remove torque converter bolts and oxygen sensor. Lower vehicle. Remove generator and starter. Remove exhaust brace bolt and exhaust manifold heat shield. Disconnect exhaust pipe from exhaust manifold.
4. Unbolt A/C compressor, and secure aside. Remove oil pan-to-bellhousing bolts. Remove transmission mount. Remove transmission-to-engine bolts. Install engine hoist, then remove engine while supporting transaxle. Separate engine from transaxle (note bolt location for reassembly reference).

Installation (Automatic Transmission)

To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Fill engine fluids, and bleed cooling system. See COOLING SYSTEM BLEEDING .

Removal

1. Disconnect negative battery cable. Disconnect electrical connectors and vacuum hoses from intake manifold components as necessary. Disconnect air intake tube. Remove throttle cable bracket.
2. Remove generator mount bolt. Remove brake booster vacuum line. Remove wiring harness from retainers on bottom of intake manifold. Remove intake manifold nuts and bolts. Remove intake manifold and gasket.

Installation

Note. Intake manifold gasket is reusable unless damaged. Numbered side of intake manifold gasket must face intake manifold.

Tighten all intake manifold nuts and bolts to specification, starting at center bolt and workiing outward in both directions. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Remove upper heat shield. Disconnect oxygen sensor connector. Raise and support vehicle. Remove exhaust manifold brace bolt. Disconnect exhaust pipe flex decoupler from manifold. DO NOT allow flex decoupler to bend more than 3 degrees in any direction, as damage will result.
2. Pull down and back on exhaust pipe to disengage it from manifold. Lower vehicle. Remove exhaust manifold nuts. Remove exhaust manifold, seals and gaskets.

To install, reverse removal procedure using NEW gaskets. Tighten bolts to specification in sequence. See TORQUE SPECIFICATIONS. (Scheme 2) If oxygen sensor was removed, coat threads with Anti-Seize Compound (5613695) before installation.

Scheme 2

1. Disconnect negative battery cable. Drain cooling system. Remove throttle body-to-air cleaner duct. Disconnect heater hose and throttle body hose from water outlet. Remove power brake vacuum hose from throttle body.
2. Disconnect electrical connectors, vacuum hoses, and coolant hoses as necessary. Remove generator mount bolt. Remove intake manifold. See «INTAKE MANIFOLD»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder).
3. Reinstall generator mount bolt. Install Engine Support Fixtures (J-28467-360). Remove exhaust manifold. See «EXHAUST MANIFOLD»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Remove ignition coil and module assembly connectors. Remove attaching bolts, and remove coil assembly from camshaft housing by pulling it straight up. (Scheme 12)
4. Disconnect camshaft position sensor connector. Remove power steering pump. Remove fuel line retaining clamp from bracket on top of intake camshaft housing. Remove fuel rail from cylinder head, and leaving fuel lines attached, position on top of master cylinder. Cover injector openings in head and injector nozzles.
5. Remove timing chain and sprocket. See «TIMING CHAIN, SPROCKETS & TENSIONER»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__timing-chain-sprockets-tensioner). Disconnect timing chain housing at intake camshaft housing but DO NOT remove from vehicle. Remove bolts attaching intake camshaft housing to cylinder head bolts in reverse of tightening sequence. (Scheme 13) Remove camshaft housing. Repeat procedure with exhaust camshaft housing.
6. Disconnect radiator inlet hose from coolant outlet and disconnect coolant temperature sensor connectors. Remove cylinder head bolts in reverse order of tightening sequence. (Scheme 3) Remove cylinder head and gasket.

Clean threads of cylinder head bolts and bolt holes. Lightly coat bolt threads with engine oil. Install NEW gasket, ensuring all holes are aligned with cylinder block. Install cylinder head and tighten cylinder head bolts to specification in sequence. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. (Scheme 3)

Scheme 3

1. Disconnect negative battery cable. Drain cooling system. Remove coolant recovery tank. Remove serpentine drive belt. Remove generator (leave wiring attached). Attach Engine Support Fixture (J-28467-360 and J-28467-400) to engine and generator stud. Remove bolts from upper half of front cover. (Scheme 4)
2. Remove engine mount assembly from timing chain end of engine. Remove engine mounting bracket adapter. Raise and support vehicle. Remove right front wheel and splash shield. Remove crankshaft balancer bolt. Remove crankshaft balancer with a puller. Remove lower bolts from front cover. Lower vehicle. Remove front cover and gaskets.

To install, reverse removal procedure. Cover gasket is reusable if not damaged. Lubricate front seal with grease before installing crankshaft balancer. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS . Fill cooling system.

Disconnect negative battery cable. Remove front cover. See FRONT COVER . Support cover, and drive seal through rear of cover. DO NOT damage cover. Note direction of seal installation. To install, use Seal Installer (J-36010).

Scheme 4

Scheme 5

TIMING CHAIN, SPROCKETS & TENSIONER

Note. This procedure has been revised due to GM service manual update (SMU) # 00-06-01-002 dated Feb, 2000

1. Disconnect negative battery cable. Remove front cover. See «FRONT COVER»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). (Scheme 5) Rotate crankshaft in normal direction of rotation (clockwise, as viewed from front of engine) until cylinder No. 1 is at TDC of compression stroke.
2. The camshaft sprocket dowel pin hole should line up with holes on timing chain housing. The crankshaft sprocket keyway should point upward. (Scheme 4) Remove timing chain guides. Raise and support vehicle. Make sure slack in chain is above tensioner assembly, then remove chain tensioner.
3. Note that timing chain must be disengaged from any wear grooves in tensioner shoe before removing shoe. Slide a screwdriver blade between chain and tensioner shoe, while pulling shoe outward (this should disengage chain from wear grooves in shoe). If timing chain is not difficult to remove, go to step 5. If it is difficult to remove timing chain shoe, go to next step.
4. Lower vehicle. Hold intake camshaft sprocket with Sprocket Wrench (J-39579) and remove sprocket bolt. Remove washer from bolt and rethread bolt into camshaft by hand. Remove camshaft sprocket using a 3-jaw puller. DO NOT attempt to pry sprocket off, or damage will result.
5. Remove tensioner assembly bolts and tensioner. Mark outer surface of timing chain and crankshaft sprocket for reassembly reference. Remove timing chain.

1. Install camshaft sprockets onto camshafts with marked surface showing (if removed). Clean old sealant off camshaft sprocket bolt threads and bolt hole in camshaft. Apply Adhesive/Sealant (12345493) to threads of camshaft sprocket bolt. Install bolt and washer. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__torque-specifications).
2. Install the camshaft sprocket bolts and washers while holding the sprockets with Tool (J- 39579). Tighten the bolts to 52 ft. lbs. (70 N.m). NOTE: Ensure camshaft sprocket alignment pins are in the cylinder block and the timing chain housing, prior to installing the timing chain housing. The camshaft sprocket alignment pins ensure proper chain housing and front cover location for correct front oil seat to crankshaft alignment.
3. Install Tool (J-36008-A) through the holes in the camshaft sprockets and into the holes in the timing chain housing. This will position the camshaft for correct timing. Use the following steps if the camshafts are out of position and must be rotated more than 1/8 turn in order to install the alignment dowel pins: The crankshaft must be rotated 90 degrees clockwise from TDC to give the valves adequate clearance to open. Once the camshafts are in position and the dowels are installed, rotate the crankshaft counter clockwise back to TDC. CAUTION: DO NOT rotate the crankshaft clockwise to TDC. Valve or piston damage could occur. The timing chain and crankshaft sprocket must be put in a specific direction for chain noise and wear considerations. The surfaces that were marked during removal should be showing when the chain and crankshaft sprocket are installed.
4. Install the timing chain over the exhaust camshaft sprocket around the coolant pump sprocket and around the crankshaft sprocket. Remove the alignment dowel pin from the intake camshaft. Use Tool (J-39579) in order to rotate the intake camshaft sprocket counter clockwise enough to allow the timing chain to slide over the intake camshaft sprocket. Release Tool (J-39579). The length of the chain between the two camshaft sprockets will tighten.
5. If properly timed, the intake camshaft alignment dowel pin will slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. Leave the alignment dowel pins installed. The keyway on the crankshaft and the mark on the cylinder block should be aligned when the slack is removed from the chain between the intake camshaft sprocket and the crankshaft sprocket. If the mark and the keyway are not aligned, move the chain one tooth forward or rearward. Remove the slack and recheck the marks. NOTE: Use the following steps in order to reset the timing chain tensioner assembly to the zero position: Reset the timing chain tensioner assembly. Insert the tensioner plunger assembly into the tensioner housing. With the tensioner plunger fully extended, turn the complete assembly upside down on a bench or other flat surface. (Scheme 7) With the plunger face against the workbench, press firmly on the bottom of the tensioner housing. Compress the plunger until the plunger is seated flush in the tensioner. (Scheme 8)
6. Check the plunger to ensure the plunger is out of the cylinder at the correct dimension. The correct dimension for the plunger to extend out of the cylinder is.070" (1.7 mm) maximum. (Scheme 8) Loosely install the tensioner assembly and bolts to the timing chain housing. (Scheme 9) Install the timing chain tensioner shoe on the stud. Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud. Tighten the timing chain tensioner bolts. DO NOT over tighten. Tighten the bolts to 89 INCH lbs. (10 N.m). CAUTION: If the timing chain tensioner plunger is not released from the installation position, engine damage will occur when the engine is started.
7. Release the timing chain tensioner plunger using the following procedure: Using a flat blade screwdriver, cotter pin remover, or a similar tool, press firmly against the face of the timing chain tensioner plunger. (Scheme 10) NOTE: If the timing chain tensioner plunger cannot be depressed, the plunger is not properly reset and the procedure for resetting the timing chain tensioner should be repeated. Depress the timing chain tensioner plunger until the plunger is bottomed out in the bore of the timing chain tensioner. (Scheme 8) Release the tensioner plunger. (Scheme 10) The plunger should press firmly against the back of the timing chain tensioner shoe. Remove Tool (J- 36008-A) from the camshaft sprockets. CAUTION: Beginning with the 1998 model year, the timing chain on the LD9 (VIN T) Twin Cam Engine is different from the chain found on earlier versions of this engine, and is not to be replaced with a timing chain from earlier model year engines. The timing sprockets were also changed beginning in 1998, and the shape of the chain links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled in the same side facing out at the time of assembly.
8. Rotate the crankshaft clockwise two full rotations. Align the crankshaft keyway with the mark on the cylinder block and reinstall the alignment dowel pins. The alignment dowel pins will slide in easily if the engine is timed correctly. Install the timing chain guides.

Note. Timing chain housing does not need to be completely removed if replacing gasket between cylinder head or cylinder block and timing chain housing.

1. Disconnect negative battery cable. Remove front cover. See «FRONT COVER»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder) . Raise and support vehicle. Drain cooling system by disconnecting heater hose from thermostat housing. Remove nuts securing water pump to timing chain housing. Remove timing chain and tensioner, making sure to mark chain and sprocket outside surfaces. See «TIMING CHAIN, SPROCKETS & TENSIONER»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__timing-chain-sprockets-tensioner) .
2. Remove fasteners attaching timing chain housing onto block. Remove 4 bolts securing oil pan onto front cover. Remove stud from lowest point on timing chain housing (if left installed, stud prevents removal of housing).
3. Lower vehicle. Hold camshaft sprockets with Camshaft Sprocket Alignment Pins (J-36008-A) and remove sprocket bolts. Remove bolts securing timing chain housing to camshaft housings. Remove timing chain housing and gaskets (if necessary, raise engine slightly from above).

1. Replace oil pan gasket if damaged. If silicone bead at corner joints is damaged, repair it by applying just enough Silicone Sealant (12345739) to restore it to its original dimension (too much sealant may cause part misalignment, resulting in oil leaks).
2. Ensure dowel pins are installed into cylinder block. Install timing chain housing with NEW gaskets (without sealer). Install and hand-tighten all timing chain housing bolts, then tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__torque-specifications) . To install remaining components, reverse removal procedure. Fill cooling system.

1. Remove timing chain housing. See «TIMING CHAIN HOUSING»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Remove snap ring securing bearing in housing. (Scheme 11) Install Remover/Installer Plate (J-36998-4) onto front side of housing, engaging alignment pins into bolt holes in housing.
2. Using Handle (J-36998-2), press sprocket out of bearing. Reposition remover/installer plate onto rear side of housing, engaging water pump studs into holes in plate. Using Remover/Installer (J-36998-1) and handle, press bearing out of housing.

Clean snap ring groove in housing. Coat surfaces of housing and NEW bearing with Sealant (12345493). Install remover/installer plate onto front side of housing. Using remover/installer and handle, press bearing into housing. Reposition remover/installer plate onto rear side of housing. Using remover/installer and handle, press idler sprocket through bearing. Install bearing snap ring. Install timing chain housing. See TIMING CHAIN HOUSING .

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Disconnect negative battery cable. Disconnect ignition coil electrical connector. Remove bolts, and remove ignition coil and module assembly by pulling it straight up. (Scheme 12) It may be necessary to use Spark Plug Wire Remover (J-36011) to break plug wire connectors loose by twisting and then pulling.
2. Disconnect camshaft position sensor connector. Remove power steering pump, and set aside (leave hoses connected). Disconnect vacuum line from fuel pressure regulator. Disconnect fuel injector harness connector. Remove fuel line clamp from top of intake camshaft housing. Remove fuel rail bolts.
3. Remove fuel rail (leave fuel lines attached). Cover injector openings in cylinder head. Cover injector nozzles. Remove timing chain and camshaft sprockets. See «TIMING CHAIN, SPROCKETS & TENSIONER»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__timing-chain-sprockets-tensioner). Remove bolts securing timing chain housing onto camshaft housing.
4. Remove bolts that secure camshaft housing cover onto camshaft housing. Working in reverse order of tightening sequence, evenly loosen and remove bolts securing camshaft housing onto cylinder head (leave 2 bolts loosely in place to keep camshaft housing in place while separating cover from housing). (Scheme 13)
5. Install 4 camshaft housing-to-cylinder head bolts into tapped holes in camshaft housing cover. Evenly tighten bolts to separate cover from housing. Remove 2 loosely installed camshaft housing bolts. Remove camshaft housing cover and seals. Discard seals.
6. Install and hand-tighten one camshaft housing bolt to keep camshaft housing in place while removing camshaft and lifters. For installation reference, note position of dowel pin (on timing chain sprocket) in relation to camshaft housing. Remove camshaft. Remove camshaft housing and lifters as an assembly. If necessary, remove lifters from camshaft housing.

Inspection

If camshaft journal diameter, lobe lift, end play or oil clearance is not within specification, replace components as necessary. See CAMSHAFT SPECIFICATIONS table under ENGINE SPECIFICATIONS. Check camshaft housing. See CAMSHAFT HOUSING under OVERHAUL.

Note. If replacing camshaft or lifters, add Engine Oil Supplement (1052367) to crankcase. If camshaft is replaced, lifters must also be replaced.

1. Ensure dowel pins aligning camshaft housing with cylinder head are installed. Install camshaft housing with a NEW gasket (no sealant required). Loosely install one camshaft housing bolt to keep camshaft housing in place while installing lifters and camshaft.
2. Coat lifters and camshaft with Prelube (12345501). Install lifters in their original locations. Install camshaft, ensuring dowel pin on timing chain sprocket is in same position as when removed. Dowel pin should point straight up and lined up with centerline of lifter bore. Install NEW Green camshaft housing cover seals into cover (no sealant is required).
3. Remove bolt installed to keep camshaft housing in place. Apply Pipe Sealant (1052080) to threads of bolts securing housing onto cylinder head and cover onto housing. Tighten camshaft housing bolts to specification in sequence. (Scheme 13) See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__torque-specifications).
4. Install timing chain housing and timing chain in reverse order of removal. Lubricate NEW "O" ring seals with engine oil, and install onto injectors. Install fuel rail. To install remaining components, reverse removal procedure.
5. If a spark plug boot connector remained on a spark plug when ignition coil and module assembly was removed, remove connector from spark plug and install it onto ignition coil and module assembly. Set ignition coil and module assembly in place, and press straight down to install assembly onto spark plugs.
6. Clean oil from threads of bolts securing assembly to camshaft housing. Apply Pipe Sealant (1052080) to ignition coil-to-camshaft housing bolt threads. To complete installation, reverse removal procedure.

Scheme 12

Scheme 13

1. Disconnect negative battery cable. Disconnect ignition coil electrical connector. Remove bolts, and remove ignition coil and module assembly by pulling it straight up. (Scheme 12) It may be necessary to use Spark Plug Wire Remover (J-36011) to break plug wire connectors loose by twisting and then pulling.
2. Disconnect oil pressure switch connector. Disconnect timing chain housing at exhaust camshaft housing but DO NOT remove from vehicle. See «TIMING CHAIN HOUSING»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Remove exhaust camshaft cover and gasket.
3. Working in reverse order of tightening sequence, evenly loosen and remove bolts securing camshaft housing to cylinder head (leave 2 bolts loosely in place to keep camshaft housing in place while separating cover from housing). (Scheme 13) Install 4 camshaft housing-to-cylinder head bolts into tapped holes in camshaft housing cover.
4. Evenly tighten bolts to separate cover from housing. Remove 2 loosely installed camshaft housing bolts. Remove camshaft housing cover and seals. Discard seals.
5. Install and hand-tighten one camshaft housing bolt to keep camshaft housing in place while removing camshaft and lifters. For installation reference, note position of dowel pin (on timing chain sprocket) in relation to camshaft housing. Remove camshaft. Remove camshaft housing and lifters as an assembly. If necessary, remove lifters from camshaft housing.

If camshaft journal diameter, lobe lift, end play or oil clearance is not within specification, replace components as necessary. See CAMSHAFT SPECIFICATIONS table under ENGINE SPECIFICATIONS. Check camshaft housing. See CAMSHAFT HOUSING under OVERHAUL.

Note. If replacing camshaft or lifters, add Engine Oil Supplement (1052367) to crankcase. If camshaft is replaced, lifters must also be replaced.

1. Ensure dowel pins aligning camshaft housing with cylinder head are installed. Install camshaft housing with NEW gasket (no sealant required). Loosely install one camshaft housing bolt to keep camshaft housing in place while installing lifters and camshaft.
2. Coat lifters and camshaft with Prelube (12345501). Install lifters in their original locations. Install camshaft, ensuring dowel pin on timing chain sprocket is in same position as when removed. Dowel pin should point straight up and lined up with centerline of lifter bore. Install NEW Orange seals into cover (no sealant is required).
3. Remove bolt installed to keep camshaft housing in place. Apply Pipe Sealant (1052080) to threads of bolts securing housing to cylinder head and cover to housing. Tighten camshaft housing bolts to specification in sequence. (Scheme 13) See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__torque-specifications).
4. Install timing chain housing and timing chain in reverse order of removal. To install remaining components, reverse removal procedure. If a spark plug boot connector remained on a spark plug when ignition coil and module assembly was removed, remove connector from spark plug and install it onto ignition coil and module assembly.
5. Set ignition coil and module assembly in place and press straight down to install assembly onto spark plugs. Clean oil from threads of bolts securing assembly to camshaft housing. Apply Pipe Sealant (1052080) to ignition coil-to-camshaft housing bolt threads. To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Remove transaxle. For M/T, see appropriate article in CLUTCHES. For A/T, see appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING.
2. On manual transaxle models, mark pressure plate in relation to flywheel for installation reference. Remove flexplate/flywheel assembly. Remove oil pan-to-seal housing bolts. Remove seal housing-to-block bolts and gasket. (Scheme 24)
3. Note direction of seal installation. Lay seal housing onto 2 wood blocks, with transaxle side of seal housing facing down. To prevent seal housing damage, ensure wood blocks that seal housing are supported across dowel pin and center bolt holes on both sides of seal opening. Using a small chisel in seal relief grooves, evenly drive seal out of seal housing without scraping sealing surface.

1. Using Crankshaft Rear Seal Installer (J-36005), press NEW seal into housing. Replace oil pan gasket if damaged. If silicone bead at corner joints is damaged, repair it by applying just enough Silicone Sealant (12345739) to restore it to its original dimension (too much sealant may cause part misalignment, resulting in oil leaks).
2. Set NEW seal housing-to-block gasket into place onto dowel pins. Lubricate NEW seal lip with engine oil. Install seal housing, but DO NOT install oil pan bolts. Tighten bolts securing seal housing onto cylinder block to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__torque-specifications) . Install and tighten oil pan-to-seal housing bolts to specification.
3. To install remaining components, reverse removal procedure. Apply Sealant (12345493) to flexplate/flywheel bolts before installing them. Align reference marks on pressure plate and flywheel (manual transmission).

1. Oil flow check valve is located below surface of cylinder block deck, near front of engine, and is accessible with cylinder head removed. (Scheme 27) Attach a slide hammer to check valve using Check Valve Remover (J-38123) or a modified common 3/16 x 4" round-head machine screw. To modify screw, grind 2 flat spots on outside diameter of screw head, parallel with screwdriver slot and 180 degrees across from each other.
2. Insert check valve remover (or modified machine screw) into check valve, then rotate tool 90 degrees so it will lock into indentations in check valve. DO NOT allow tools to contact check ball as it can drop into engine oil galleries. Pull check valve out of its bore.

If check ball is missing, it has dropped into oil galleries and must be retrieved before installation. Using slide hammer and check valve remover (opposite end), or a hammer and drift punch, drive NEW check valve into its bore until it is seated (normally, check valve will seat slightly below surface). A distinct change of sound will result when check valve seats.

To remove and install valve lifters, remove camshafts and camshaft housings. See INTAKE CAMSHAFT & HOUSING . Also See EXHAUST CAMSHAFT & HOUSING .

RADIATOR (ALERO & GRAND AM)

Note. When adding coolant, it is important that you use GM Goodwrench DEX-COOL™ coolant. If coolant other than DEX-COOL™ is added to the system, the engine coolant will require change sooner: at 30,000 miles (50 000 km) or 24 months.

1. Disconnect negative battery cable. Disconnect positive battery cable. Remove the retainer bolt and retainer. Remove the battery and battery insulator from vehicle.
2. Remove the battery tray screws and the battery tray.
3. Evacuate the A/C system using approved recover and recycling procedures. See «GENERAL MOTORS»(/chevrolet/cavalier/iii-1995-2005/remont/general-servicing-all-makes/#hvac-system-general-servicing-procedures) under EVACUATING A/C SYSTEM in GENERAL SERVICING article in HEATING & AIR CONDITIONING.
4. Drain the cooling system. Recover the coolant.
5. Remove the upper radiator hose.
6. Remove the upper transaxle cooler line.
7. Remove the coolant surge tank hose.
8. Remove the condenser inlet fitting from the discharge hose.
9. Disconnect the cooling fan electrical connection.
10. Raise the vehicle. See «JACKING & HOISTING»(/chevrolet/cavalier/iii-1995-2005/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures) in SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
11. Remove the lower closeout panel.
12. Remove the lower radiator hose from the radiator.
13. Remove the lower transaxle cooler line.
14. Remove the evaporator line from the condenser outlet.
15. Remove the lower radiator mounting panel.
16. Remove the radiator, fan and condenser as an assembly from the vehicle.
17. Remove the condenser from the radiator.
18. Remove the fan shroud from the radiator.

1. Install the fan shroud to the radiator.
2. Install the condenser to the radiator. Tighten the bolt to 44 INCH lbs. (5 N.m).
3. Install the radiator, fan, and condenser as an assembly to the vehicle.
4. Install the lower radiator mounting panel. Tighten the bolts to 89 INCH lbs. (10 N.m)
5. Install the condenser outlet to the evaporator line. Tighten the bolt to 18 ft. lbs. (25 N.m).
6. Install the lower radiator hose to the radiator.
7. Install the lower closeout panel.
8. Lower the vehicle. Install the cooling fan electrical connection.
9. Install the lower transaxle cooler line. Tighten the bolt to 22 ft. lbs. (30 N.m).
10. Install the condenser inlet fitting to the discharge hose. Tighten the bolt to 18 ft. lbs. (25 N.m).
11. Install the coolant surge tank hose.
12. Install the upper transaxle cooler line. Tighten the bolt to 22 ft. lbs. (30 N.m).
13. Install the upper radiator hose.
14. Refill the cooling system.
15. Recharge the A/C system. See «GENERAL MOTORS»(/chevrolet/cavalier/iii-1995-2005/remont/general-servicing-all-makes/#hvac-system-general-servicing-procedures) under CHARGING A/C SYSTEM in GENERAL SERVICING article in HEATING & AIR CONDITIONING.
16. Install the battery tray.
17. Install the battery.
18. Start engine. Bleed cooling system. See «COOLING SYSTEM BLEEDING»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__cooling-system-bleeding) . Inspect the cooling system for leaks.

Note. After servicing the cooling system, and if the vehicle is equipped with an intermittent low coolant light, an occasional low coolant light may be encountered during some extreme driving maneuvers. This complaint should be eliminated by removing the surge tank cap and adding coolant to a level just at or above the full cold line when the system is cold.

RADIATOR (CAVALIER & SUNFIRE)

Note. When adding coolant, it is important that you use GM Goodwrench DEX-COOL™ coolant. If coolant other than DEX-COOL™ is added to the system, the engine coolant will require change sooner: at 30,000 miles (50 000 km) or 24 months.

1. Disconnect the negative battery cable.
2. Disable the SIR system as follows: For 2000, See «DISABLING & ACTIVATING AIR BAG SYSTEM»(/chevrolet/cavalier/iii-1995-2005/remont/airbag/#supplemental-inflatable-restraint-system__disabling-activating-air-bag-system) . For 2001, see «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-150087-S03945837902002110400000) in AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.
3. Drain the engine coolant. Recover the coolant.
4. Remove the hood latch support from the radiator upper tie bar.
5. Remove the right and left headlamp assemblies by removing the upper air intake splash shield. Remove the headlamp assembly bolts. Remove the socket/bulb. Remove the housing/lens assembly from the bracket. Remove the screws and the adjusters if necessary.
6. Remove the radiator upper mounting bolts and the upper radiator mounts
7. Raise and suitably support the vehicle. See «JACKING & HOISTING»(/chevrolet/cavalier/iii-1995-2005/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures) in SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
8. Remove the SIR Connector Position Assurance (CPA) from the inflatable restraint front end forward discriminating sensor harness connector. Disconnect the inflatable restraint front end discriminating sensor harness connector from the sensor. Note routing of harness for installation reference.
9. Remove the cooling fan assembly. Raise the vehicle. Remove the cooling fan mounting bolt. Disconnect the electrical connector from the cooling fan. Remove the cooling fan assembly by pulling the fan assembly out through the bottom of the vehicle.
10. Disconnect the radiator outlet hose from the radiator.
11. Disconnect the lower transmission oil cooler line from the radiator.
12. Lower the vehicle.
13. Remove the hood latch support bracket and the forward discriminating sensor with the harness.
14. Disconnect the upper transmission oil cooler line from the radiator.
15. Disconnect the radiator inlet hose from the radiator.
16. Disconnect the surge tank inlet hose and the clamp from the radiator.
17. Remove the condenser from the radiator, if equipped. It is not necessary to discharge the A/C System.
18. Remove the radiator assembly from the vehicle.

1. Install the radiator assembly to the vehicle.
2. Install the condenser to the radiator.
3. Connect the surge tank overflow hose to the radiator.
4. Install the hood latch bracket. Route the forward discriminating sensor harness.
5. Raise the vehicle.
6. Install the cooling fan assembly.
7. Connect the lower transmission oil cooler line to the radiator. Tighten the lower transmission oil cooler line to 27 ft. lbs. (36 N.m).
8. Connect the radiator outlet hose to the radiator.
9. Connect the forward discriminating sensor harness connector.
10. Lower the vehicle.
11. Connect the radiator inlet hose to the radiator.
12. Connect the upper transmission oil cooler line to the radiator. Tighten the upper transmission oil cooler line to 27 ft. lbs. (36 N.m).
13. Install the upper radiator mount bolts to the upper tie bar. Tighten the radiator upper mount bolts to 89 INCH lbs. (10 N.m).
14. Install the hood latch support.
15. Install the right and the left headlamp assemblies.
16. Install and adjust the hood latch assembly.
17. Refill the cooling system.
18. Enable the SIR system.
19. Connect the negative battery cable. Tighten the negative battery cable bolt to 11 ft. lbs. (15 N.m).
20. Start the engine. Bleed cooling system as necessary. See «COOLING SYSTEM BLEEDING»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__cooling-system-bleeding) . After the engine reaches normal operating temperature, inspect for coolant leaks.
21. Inspect the headlamp for proper operation. Adjust headlamps if necessary.

Note. After servicing the cooling system, and if the vehicle is equipped with an intermittent low coolant light, an occasional low coolant light may be encountered during some extreme driving maneuvers. This complaint should be eliminated by removing the surge tank cap and adding coolant to a level just at or above the full cold line when the system is cold.

THERMOSTAT

Note. When adding coolant, it is important that you use GM Goodwrench DEX-COOL™ coolant. If coolant other than DEX-COOL™ is added to the system, the engine coolant will require change sooner: at 50 000 km (30,000 miles) or 24 months.

1. Disconnect the negative battery cable.
2. Drain and recover the coolant.
3. Remove the exhaust manifold heat shield.
4. Remove the coolant inlet housing bolts through the exhaust manifold.
5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
6. Remove the coolant inlet housing stud from the oil pan. (Scheme 14)
7. Remove the tire and wheel assembly.
8. Remove the splash shield.
9. Remove the bolts from the transaxle-to-engine block brace. Remove the brace.
10. Remove the coolant housing pipe.
11. Remove the thermostat. (Scheme 15)
12. Clean the mating surfaces.

Scheme 14

Scheme 15

1. Install the thermostat. (Scheme 15)
2. Install the coolant housing pipe.
3. Install the transaxle-to-engine block brace and secure with the bolts.
4. Install the splash shield.
5. Install the tire and wheel assembly.
6. Install the gasket. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
7. Install the coolant inlet housing stud to the oil pan. (Scheme 14) Tighten the bolt to 26 Nm (19 lb ft).
8. Lower the vehicle.
9. Install the coolant inlet housing bolts through the exhaust manifold. Tighten the bolt to 14 Nm (124 lb in).
10. Install the exhaust manifold heat shield.
11. Fill the cooling system. Refer to «COOLING SYSTEM BLEEDING»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__cooling-system-bleeding).
12. Connect the negative battery cable. Tighten the bolt to 16 Nm (12 lb ft).
13. Inspect the system for leaks.

1. Water pump is driven by timing chain idler and is mounted on rear of timing chain housing. (Scheme 16) Disconnect negative battery cable. Drain cooling system. Disconnect oxygen sensor connector.
2. Remove upper exhaust manifold heat shield. Remove exhaust manifold brace. Remove lower exhaust manifold heat shield. Loosen exhaust manifold-to-exhaust manifold spring loaded nuts. Remove radiator outlet pipe to water pump cover bolts. Disconnect exhaust pipe from manifold.
3. Pull down on exhaust pipe to disconnect if from exhaust manifold bolts. See «EXHAUST MANIFOLD»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Disconnect outlet pipe from oil pan and transaxle. If equipped with manual transaxle, remove exhaust manifold brace. Leave lower radiator hose attached and pull down on radiator outlet pipe to disengage from water pump. Leave outlet pipe hanging.
4. Lower vehicle. Remove exhaust manifold to cylinder head nuts. Remove exhaust manifold. Remove timing chain front cover. See «FRONT COVER»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Remove timing chain tensioner. See «TIMING CHAIN, SPROCKETS & TENSIONER»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__timing-chain-sprockets-tensioner). Remove bolts securing water pump cover to cylinder block. Remove water pump-to-timing chain housing nuts.
5. Remove water pump attaching nuts. Remove water pump and cover assembly. Separate components as necessary.

Note. Before installing water pump, read entire installation procedure. It contains important information about tightening sequences that affect sealing.

1. If cover was separated from body during removal, join these components with a NEW gasket, and hand-tighten bolts. Apply Bearing Grease (1051344) to splines of water pump drive. Set cover and body assembly into position.
2. Install and hand-tighten bolts securing cover to cylinder block. Install and hand-tighten nuts securing body to timing chain housing. Lubricate outlet pipe "O" ring with antifreeze. Connect outlet pipe. Install and hand-tighten bolts.
3. Tighten bolts and nuts to specification in following sequence. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__torque-specifications) . Pump Assembly-To-Timing Chain Housing Nuts. Pump Cover-To-Pump Body Bolts. Pump Cover-To-Cylinder Block Bolts (Bottom Bolt First). Outlet Pipe-To-Cover Bolts.
4. To complete installation, reverse removal procedure. Fill cooling system.

Scheme 16

1. Disconnect negative battery cable. Install engine support fixture. Remove engine mount. Raise engine approximately 1.5" (3.8 cm) Raise and support vehicle. Drain crankcase. Drain cooling system. Remove flywheel cover. Remove right front wheel. Remove splash shield. Remove serpentine drive belt. Remove air conditioning compressor lower bolts.
2. Remove transaxle-to-engine brace. Remove radiator outlet pipe bolts. Remove outlet pipes from oil pan. Remove exhaust manifold brace.
3. Remove bolt and nut securing oil pan to flywheel cover. Remove flywheel cover stud (for clearance during removal). Disconnect radiator outlet pipe from lower radiator hose and oil pan. Disconnect oil level sensor connector. Remove oil pan bolts, pan and gasket.

If oil pan gasket is not damaged, reuse it. Install oil pan and gasket. Loosely install oil pan bolts. Place spacer in approximate installed location, but allow clearance to tighten pan bolt located directly above spacer. Tighten oil pan bolts to specification in the following sequence. (Scheme 17) See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 17

Remove negative battery cable. Remove oil pan. See OIL PAN . Remove balance shaft cover retainers and cover. To install, reverse removal procedure.

Disconnect negative battery cable. Remove engine oil pan. See OIL PAN. Remove balance shaft chain cover. See BALANCE SHAFT CHAIN COVER. Remove balance shaft chain cover. Remove tensioner assembly. (Scheme 23)

1. Install chain guide. Loosely install adjustment bolt at chain guide. Adjust chain tension as follows: Insert a.040" (1.0 mm) brass feeler gauge between chain and guide. (Scheme 24) Press chain against guide with 3 lbs. (1.4 kg) of force.
2. Tighten chain guide adjustment bolt to specification. Press chain against guide with 3 lbs. (1.4 kg) of force.
3. Tighten chain guide adjustment bolt to specification. Install chain cover. Tighten cover nut and bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__torque-specifications). To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Remove oil pan. See «OIL PAN»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Remove balance shaft cover retainers and cover. Loosen but do not remove chain tensioner. Remove oil pump cover. Remove oil pump. Rotate crankshaft until No. 1 piston is at TDC. Install Balance Shaft Holder (41088) to prevent shafts from turning. (Scheme 20)
2. Remove balance shaft driven sprocket bolt. Mark outside surfaces of sprockets for reassembly reference, and remove driven sprocket. Remove balance shaft assembly bolts and remove assembly.

1. Check end play with a dial indicator. Set up indicator to read off back of shafts. Press against one shaft and note movement. Repeat for other shaft. Backlash should be .0003-.0034" (.008-.086 mm).
2. Note that balance shafts must be pulled in same direction to ensure proper reading. If out of specification, check thrust plate for wear. If end play is excessive and thrust plate is not worn, replace balance shafts.

Note. Balance shafts and drive chains must be replaced as a pair.

1. Install balance shaft assembly to engine and tighten to specification. Use Sealer (12345493) on bolts. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__torque-specifications). Install balance shaft driven sprocket. Tighten NEW left-hand thread bolt to specification, with Balance Shaft Holder (41088) installed to prevent shafts from turning. (Scheme 20) See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__torque-specifications).
2. Install oil pump. Install balance shaft tensioner and tighten and adjust. See «BALANCE SHAFT CHAIN TENSIONER»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Install balance shaft chain cover. See «BALANCE SHAFT CHAIN COVER»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). To complete installation, reverse removal procedure.

1. Remove engine and transaxle. See «ENGINE»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Remove starter motor. Remove transaxle from engine. Remove flexplate/flywheel. Remove crankshaft balancer from engine. See «FRONT COVER»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Install engine to stand.
2. Remove bolts and remove ignition coil and module assembly by pulling it straight up. (Scheme 12) Remove spark plugs. Remove engine front cover. See «FRONT COVER»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Rotate engine to "timed" position and remove timing chain. (Scheme 4)
3. Remove timing chain housing. See «TIMING CHAIN HOUSING»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Rotate engine on stand 180 degrees and remove oil pan. See «OIL PAN»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Remove balance shaft assembly. See «BALANCE SHAFT ASSEMBLY»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder). Remove crankshaft and balance shaft drive chain. (Scheme 22)

Install crankshaft and balance shaft drive chain. Install balance shaft assembly. See BALANCE SHAFT ASSEMBLY . Install oil pan. Rotate engine 180 degrees on stand. Install timing chain housing. See TIMING CHAIN HOUSING . To complete installation, reverse removal procedures.

Remove balance shaft assembly. See BALANCE SHAFT ASSEMBLY. Remove attaching bolts and split housings. (Scheme 18) Remove shafts, bearings and thrust plate from housing.

1. Clean all parts in solvent. Inspect housing for cracks, scored bearing bores and damaged threads. If housing is damaged, replace entire assembly. Check all sprocket teeth for bent, broken, chipped or other damage. Check sprocket for burrs, damaged bolt hole or scored surfaces. Inspect shafts for scores or burrs, cracks or missing pieces.
2. Inspect balance shaft journals for correct diameter, and out-of-round. Check balance shaft gear backlash. See inspection procedure under «BALANCE SHAFT ASSEMBLY»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder) . Inspect bearings for damage. Determine clearance with Plastigage or by measuring journal and bearing diameters. Bearing clearance should be .0017-.0044" (.044-.111 mm).
3. Inspect thrust plate for gouges or burrs and measure thickness. Thrust plate thickness should be .1159-.1199" (2.945-3.045 mm).

1. Install thrust plate and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__torque-specifications). Install bearing halves into housing and lubricate. Install balance shaft and balance shaft gear subassemblies into housing. Make sure timing marks line up. (Scheme 19)
2. Install upper housing half to lower half. Tighten bolts to initial torque of 44 INCH lbs. (5 N.m). Final tightening will be accomplished after installation on engine. (Scheme 21) To complete installation, reverse removal procedure. NOTE: DO NOT install oil pump pick-up screen until housing bolts have been tightened to final specification.

1. Place No. 1 piston at TDC. Rotate crankshaft an additional 90 degrees in either direction (keyway on crankshaft should be aligned with split line of main bearing). (Scheme 20) Rotate balance shafts as necessary, then install Balance Shaft Holder (J-41088) onto ends of balance shafts. Balance shafts are now timed in relation to crankshaft.
2. Install chain and driven sprocket onto balance shaft. If installing old sprocket, ensure same surface of sprocket, as when removed, faces balance shaft. If installing NEW sprocket, either surface of sprocket can be placed against balance shaft.
3. Install and finger-tighten (left-hand threads). Install chain guide. While tightly pressing chain guide against chain, temporarily install and tighten chain guide adjustment bolt. Tighten NEW sprocket bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder__torque-specifications). Remove balance shaft holder from ends of balance shafts.

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

OVERHAUL

Note. For repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES article in GENERAL INFORMATION.

Gasket Surfaces

Using a straightedge and feeler gauge, measure warpage of cylinder head deck surface and manifold surfaces. If warpage is less than .003" (.076 mm), cylinder head is okay and does not require resurfacing. If warpage is .003-.010" (.076-.25 mm), resurface head. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. If warpage exceeds .010" (.25 mm), replace cylinder head.

Valve Springs

Check squareness, free length and pressure of valve springs. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. Replace any spring that is not within specification.

Valve Stem Oil Seals

Remove seals with Seal Remover (J-36017). Install seals with Seal Installer (J-36007).

Valve Guides

If stem-to-guide oil clearance exceeds specification, ream valve guide with Reamer (J-36019-A) and/or replace valve. See VALVES & VALVE SPRINGS and CYLINDER HEAD tables under ENGINE SPECIFICATIONS. Information on valve guide replacement is not available from manufacturer.

Valve Seats

Set seat angle and seat width to specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Remove only enough metal to clean seat. Valve seat replacement information is not available from manufacturer.

Valve Face

If resurfacing valve face, remove only enough metal to clean face. Set face angle to specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Dimensions

If valve dimensions are not as specified, replace valve. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Seat Correction Angles

If seat and face make contact too close to valve stem, grind seat with a 20-degree stone. If seat and face make contact too close to valve margin, grind seat with a 70-degree stone.

Valve Installed Height

Valve installed height is distance from tip of valve stem to top of camshaft housing. If installed height is not as specified, grind valve seat or replace valve as necessary. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

CAMSHAFT HOUSING

Measure valve lifter O.D. and lifter bore I.D. Determine oil clearance. Inspect camshaft housing warpage. Replace components if necessary. See VALVE LIFTERS table under ENGINE SPECIFICATIONS.

Piston & Rod

Orientation Arrow on top of piston must face front of engine. Oil hole in connecting rod must face exhaust manifold side of engine. (Scheme 25)

Piston Pin

Remove retainer rings from each end of pin bore. No special tools are required to remove and install piston pin. If piston fit is not within specification, replace piston and/or pin. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.

Fitting Pistons

Measure diameter of piston at a 90-degree angle to piston pin, at .47" (12 mm) up from center of piston skirt tail. If piston clearance exceeds specification, replace pistons and/or machine cylinders. See PISTONS, PINS & RINGS and CYLINDER BLOCK tables under ENGINE SPECIFICATIONS.

Piston Rings

If end gap or side clearance exceeds specification, replace piston and/or rings. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Ring No. 2 (second ring) must be installed with mark on ring flat facing upward. Before installing piston, stagger ring end gaps 120 degrees apart. (Scheme 25)

Scheme 25

Rod Bearings

1. Mark cylinder number on bearing caps for reassembly reference. If connecting rod side clearance exceeds specification, replace connecting rod and/or crankshaft as necessary. See «CONNECTING RODS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder) table under ENGINE SPECIFICATIONS.
2. If connecting rod journal dimensions are not within specification, replace crankshaft. If oil clearance is not within proper specification, replace connecting rod bearings. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/chevrolet/cavalier/iii-1995-2005/remont/mechanical/#engine-mechanical-24l-4-cylinder) table under ENGINE SPECIFICATIONS.

Crankshaft & Main Bearings

Main bearing caps are numbered 1 through 5. If main bearing journal dimensions are not within specification, replace crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. If oil clearance is not within specification, replace bearings.

Thrust Bearing

Thrust bearing is part of main bearing No. 3. Using a rubber mallet, tap crankshaft forward then rearward to seat thrust bearing. With main bearing cap bolts tight, check crankshaft end play. If end play exceeds specification, replace main bearing No. 3 and/or crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Crankshaft Balance Shaft Drive Sprocket

1. Inspect sprocket. If replacement is required, drill a hole between 2 teeth of sprocket. Split gear with a chisel to remove it from crankshaft. Ensure crankshaft is free of burrs.
2. Preheat oven to 392°F (200°C) for one hour. Smear some Tempilstik (J-24731-425) material onto teeth of replacement sprocket. Heat gear in oven for 25-30 minutes or until Tempilstik starts to melt. Install gear on crankshaft, ensuring it is fully seated against counterweight.

Cylinder Bores

Measure diameter of cylinder bore at midstroke. If cylinder dimensions are not as specified, machine cylinder as necessary and/or replace piston. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.

Cylinder Block Deck Warpage

If cylinder block deck warpage exceeds specification, machine cylinder head. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. DO NOT remove more than .010" (.25 mm) of material from original surface.

ENGINE LUBRICATION SYSTEM

Oil pump is located near rear end of balance shaft housing (accessible after oil pan has been removed). A chain at rear end of crankshaft drives long balance shaft, which drives short balance shaft. Short balance shaft drives oil pump. Oil is forced through oil filter to main gallery. (Scheme 27) If oil filter becomes clogged, a by-pass valve in cylinder block opens.

From main gallery, oil is distributed to balance shafts, crankshaft, timing chain hydraulic tensioner, lifters, and camshaft. Main bearings and connecting rod bearings are oiled through passages in crankshaft. Cylinder walls are oiled through a hole in connecting rod. Oil passes through oil flow check valve, into cylinder head, and then into each camshaft housing.

Oil is fed to valve lifters and camshaft bearings. Crankcase Capacity Oil capacity is 4 qts. (3.8L) without oil filter. When checking oil pressure, ensure that engine is at normal operating temperature. Oil pressure should be at least 10 psi (.7 kg/cm 2 ) at 900 RPM, or 30 psi (2.1 kg/cm 2 ) at 2000 RPM.

Scheme 26

Scheme 27

OIL PUMP

Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove balance shaft chain cover. See BALANCE SHAFT CHAIN COVER under REMOVAL & INSTALLATION. Remove chain tensioner. See BALANCE SHAFT CHAIN TENSIONER under REMOVAL & INSTALLATION. Remove oil pump cover and oil pump.

Disassembly & Inspection

Remove oil pump cover. (Scheme 26) Remove oil pump body and gerotor. To remove relief valve, carefully remove drift pin (valve is under spring pressure). If oil pump components are damaged or if clearances and component dimensions are not within specification, replace oil pump. See OIL PUMP SPECIFICATIONS table.

Reassembly & Installation

Coat components with oil. Pack oil pump cavities with petroleum jelly (to prime oil pump). To reassemble and install, reverse removal and disassembly procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

OIL PUMP SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS SPECIFICATIONS

CONNECTING RODS

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

PISTONS, PINS & RINGS

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK

ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT HOUSING SPECIFICATIONS

CAMSHAFT HOUSING

VALVE LIFTERS SPECIFICATIONS

VALVE LIFTERS

BALANCE SHAFTS SPECIFICATIONS

BALANCE SHAFTS

See also:
• ENGINE OVERHAUL PROCEDURES
• ENGINE MECHANICAL
• CAVALIER & SUNFIRE
• ALERO, GRAND AM & MALIBU
• GENERAL MOTORS
• JACKING & HOISTING
• DISABLING & ACTIVATING AIR BAG SYSTEM
• ENGINE IDENTIFICATION CODES
• FUEL PRESSURE RELEASE
• TORQUE SPECIFICATIONS
• COOLING SYSTEM BLEEDING
• TIMING CHAIN, SPROCKETS & TENSIONER
• CAMSHAFT HOUSING