Cavalier 2.2

1998 Chevrolet Cavalier
1998-99 ENGINES 2.2L 4-Cylinder
1998-99 ENGINES
2.2L 4-Cylinder
ENGINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER (VIN)
The VIN is stamped on a metal pad located near lower left corner of windshield. A 4 in the eighth character
of VIN identifies 2.2L 4-cylinder engine.
PARTIAL VIN
A partial VIN (9 characters) is stamped on lower left side of cylinder block, at cylinder block-to-
transmission flange. See Fig. 1.
Fig. 1: Locating Engine Partial VIN

Courtesy of GENERAL MOTORS CORP.
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
Engine is equipped with non-adjustable hydraulic valve lifters.
TROUBLE SHOOTING
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NOTE: To trouble shoot engine mechanical components, see appropriate table in

TROUBLE SHOOTING article in GENERAL INFORMATION.
REMOVAL & INSTALLATION
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See appropriate COMPUTER
RELEARN PROCEDURES article in GENERAL INFORMATION before
disconnecting battery.
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.
ENGINE MOUNT
Tools Required
J 28467-360 Engine Support Fixture
Removal Procedure
CAUTION: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before
servicing any electrical component. Disconnect the negative battery
cable to prevent an electrical spark should a tool or equipment come in
contact with an exposed electrical terminal. Failure to follow these
precautions may result in personal injury and/or damage to the vehicle
or its components.
For Vehicles equipped with OnStar® (UE1) with Back Up Battery:
The Back Up Battery is a redundant power supply to allow limited
OnStar® functionality in the event of a main vehicle battery power
disruption to the VCIM (OnStar®module). Do not disconnect the main
vehicle battery or remove the OnStar® fuse with the ignition key in any
position other than OFF. Retained accessory power (RAP) should be
allowed to time out or be disabled (simply opening the driver door
should disable RAP) before disconnecting power. Disconnecting power
to the OnStar® module in any way while the ignition is On or with RAP
activated may cause activation of the OnStar® Back-Up Battery (BUB)
system and will discharge and permanently damage the back-up
battery. Once the Back-Up Battery is activated it will stay on until it has
completely discharged. The BUB is not rechargeable and once
activated the BUB must be replaced.
1. Disconnect the negative battery cable.

2. Install the J 28467-360
3. Raise the engine at the front lift hook in order to remove the engine weight from the engine mount
assembly using the J 28467-360 .
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Fig. 2: Coolant Recovery Tank Bolt

4. Remove the one bolt attaching the coolant recovery tank. Position the tank aside with the hoses
connected.
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Fig. 3: Engine Mount Assembly And Drive Belt Tensioner Bracket

5. Remove the engine mount assembly to the drive belt tensioner bracket
6. Remove the two nuts on top of the engine mount assembly
7. Remove the engine mount assembly to the body nuts
8. Remove the engine mount assembly bracket
9. Remove the engine mount assembly
Installation Procedure
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Fig. 4: Engine Mount Assembly And Drive Belt Tensioner Bracket

1. Install the engine mount assembly

2. Install the engine mount assembly bracket
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.
3. Install the engine mount assembly to body nuts. Tighten the nuts to 75 N.m (55 lb ft).
4. Install the engine mount assembly to the drive belt tensioner bracket bolts. Tighten the bolts to 60 Nm
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(44 lb ft) + 90 degrees.
Fig. 5: Coolant Recovery Tank Bolt

5. Install the coolant recovery tank.

6. Remove the J 28467-360
7. Connect the negative battery cable. Tighten the bolts to 16 Nm (12 lb ft).
FUEL PRESSURE RELIEF
1. Loosen fuel tank filler cap to release tank vapor pressure (DO NOT tighten at this time). On Cavalier
and Sunfire, raise and support vehicle and disconnect fuel pump electrical connector at fuel tank. On
S10 Pickup and Sonoma, remove fuel pump relay. Relay is located behind glove box.
2. Start and run engine until engine stops. Engage starter for at least 3 seconds to ensure remaining fuel
pressure is released. Disconnect negative battery cable. Reconnect fuel pump connector or install fuel
pump relay with key in off position. Since some residual pressure may exist in fuel system, Cover fuel
lines using shop towel before disconnecting.
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ENGINE
NOTE: This procedure for Cavalier and Sunfire involves removing engine and
transaxle as an assembly from the bottom of the vehicle.
Removal & Installation (Cavalier & Sunfire)
1. Release fuel system pressure. See FUEL PRESSURE RELIEF. Disconnect negative battery cable.
Drain cooling system. Remove air cleaner and intake duct.
2. Remove upper radiator hose. Disconnect engine wiring harness from engine and transmission.
Disconnect transaxle shift control cable from transaxle. Disconnect accelerator and cruise control
cables. Remove coolant surge tank and disconnect vacuum line near master cylinder. Install Engine
Support Fixture (J-28467-360). Raise and support vehicle. Remove front wheels and inner splash
shields.
3. Disconnect exhaust pipe from exhaust manifold and catalytic converter. Drain engine oil and transaxle
oil. Remove wheel speed sensors from lower control arms. Separate lower ball joints from steering
knuckles. Separate tie rod ends from struts. Disconnect brakelines from crossmember. Remove drive
axles from transaxle. Remove A/C compressor (leave hoses connected).
4. Remove lower engine mount strut from crossmember. Disconnect remaining wiring harness from
bottom of engine and transaxle. Disconnect power steering hoses and flexible coupling joint from rack
and pinion assembly. Disconnect wiring harness from crossmember. Remove crossmember extension
brace. Remove splash shield from crossmember. Remove 6 crossmember bolts and remove
crossmember with steering rack and lower control arms attached. See Fig. 6.
5. Disconnect heater hoses at firewall. Disconnect fuel lines from engine. Disconnect transmission
cooler lines from transaxle. Remove transaxle mount. Remove engine mount assembly. Lower vehicle
and support engine/transaxle with transaxle table. Remove Engine Support Fixture (J-28467-360).
Raise vehicle to remove engine/transaxle from engine compartment. To install, reverse removal
procedure. See Fig. 27. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS
table.
Removal & Installation (S10 Pickup & Sonoma)
Disconnect under hood light. Remove vacuum reservoir from hood. Disconnect windshield washer
fluid line from hood. Remove hood. Raise vehicle.
2. Remove exhaust pipe from exhaust manifold and catalytic converter. Drain engine oil and coolant.
Remove braces from engine to transmission. Remove starter motor. Remove bell housing bolts.
Remove transmission from vehicle. For M/T, see appropriate article in CLUTCHES. For A/T, see
TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING.
3. Remove O2 sensor. Remove rear generator brace. Disconnect ground straps from engine block.
Remove serpentine belt. Remove A/C compressor, and lay it aside (leave hoses connected). Remove
air intake duct. Remove radiator.
4. Remove power steering pump and set aside. Disconnect heater hoses from heater core. Disconnect
necessary vacuum hoses. Disconnect accelerator and cruise control cables. Remove EGR valve.
Disconnect positive battery cable from battery and disconnect from mega fuse, leave cable attached to
engine. Remove bolt for rear wiring harness bracket from intake manifold. Disconnect wiring harness
from engine. Disconnect fuel lines from engine.
5. Install engine hoist. Raise engine slightly. Remove left engine mount through-bolt. Remove right
engine mount through-bolt. Remove engine from vehicle. To install, reverse removal procedure.
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Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table.
Fig. 6: Removing Crossmember Assembly

INTAKE MANIFOLD
Removal (Cavalier & Sunfire)

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Remove air cleaner duct, resonator and resonator bracket. Remove accelerator and cruise control
cables with bracket. Disconnect vacuum hoses and electrical connectors from throttle body and intake
manifold.
2. Remove throttle body. Remove fuel lines from fuel rail. Remove fuel rail retaining bolts. Remove nuts
and bolts securing intake manifold to cylinder head. Remove intake manifold.
Removal (S10 Pickup & Sonoma)
Remove air cleaner outlet resonator. Remove EGR pipe.
2. Disconnect vacuum hoses, electrical connectors, and fuel lines from intake manifold and throttle
body. Remove accelerator and cruise control cables. Remove nuts and bolts securing intake manifold
to cylinder head. Remove intake manifold.
Installation
To install, reverse removal procedure. Use a NEW gasket. Tighten nuts and bolts to specification in
sequence. See TORQUE SPECIFICATIONS. See Fig. 7.
Fig. 7: Intake Manifold Tightening Sequence

EXHAUST MANIFOLD
Disconnect negative battery cable. Disconnect oxygen sensor electrical connector. Remove serpentine belt.
Remove generator rear brace and generator assembly. Remove radiator inlet pipe. Raise and support vehicle.
Disconnect exhaust pipe from exhaust manifold. Lower vehicle. Remove oil fill tube assembly. Remove
heater outlet hose assembly nut from exhaust manifold. Remove exhaust manifold nuts. Remove exhaust
manifold.
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Disconnect negative battery cable. Remove serpentine belt. Remove A/C compressor and set aside (do not
disconnect hoses). Remove power steering pump, and set aside (do not disconnect hoses). Disconnect
exhaust pipe from exhaust manifold. Remove oil fill tube assembly. Disconnect O2 sensor electrical
connection. Remove exhaust manifold nuts. Remove exhaust manifold and gasket.
Installation
To install, reverse removal procedure. Use NEW gasket. Tighten nuts to specification. See TORQUE
SPECIFICATIONS table.
CYLINDER HEAD
NOTE: When removing valve train components, keep them in order to ensure
installation in same location.
Remove air cleaner and intake duct. Remove serpentine drive belt. Remove upper engine mount.
Remove intake manifold. See INTAKE MANIFOLD. Remove exhaust manifold. See EXHAUST
MANIFOLD.
2. Drain cooling system. Remove valve cover, rocker arms and push rods. Remove generator rear brace
and generator. Remove power steering pump and set aside with lines attached. Remove radiator inlet
pipe. Remove ignition coil assembly and accessory bracket. Remove spark plug wires. Install Engine
Support Fixture (J-28467-360). Remove cylinder head bolts. Remove cylinder head.
Remove air intake duct. Disconnect exhaust pipe from exhaust manifold. Remove serpentine belt.
Drain cooling system. Remove power steering pump and set aside with hoses attached. Remove
exhaust manifold. See EXHAUST MANIFOLD.
2. Remove upper radiator hose and disconnect heater hoses from heater core. Remove rear generator
bracket and generator. Remove cooling fan and serpentine belt idler pulley. Remove heater hose pipe
bracket bolt from cleaner outlet resonator bracket and remove thermostat housing. Remove accessory
bracket. Remove valve cover, rocker arms and push rods. Disconnect fuel lines from fuel rail. Remove
cylinder head bolts. Remove cylinder head.
Inspection
Inspect cylinder head for warpage at head gasket surface and manifold surfaces. See CYLINDER HEAD
table under ENGINE SPECIFICATIONS. DO NOT remove more than .010 (.25 mm) of material from head
gasket surface.
Installation
Clean threads of cylinder head bolts and cylinder block holes. Install NEW head gasket. Install cylinder
head. Tighten cylinder head bolts to specification in proper sequence. See TORQUE SPECIFICATIONS.
See Fig. 8. To complete installation, reverse removal procedure.
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Fig. 8: Cylinder Head Bolt Tightening Sequence

FRONT COVER
1. Disconnect negative battery cable. Remove serpentine belt. Remove serpentine belt tensioner. Install
Engine Support Fixture (J-28467-360). Remove front engine mount. Remove rear generator brace and
generator. Remove power steering pump and set aside with hoses attached. Remove oil pan, See OIL
PAN.
2. Remove right front wheel. Remove engine splash shield. Remove bolt from center of crankshaft
pulley. Using puller (J-24420-B) remove crank shaft pulley. Remove remaining bolts securing front
cover to block and remove front cover.
Disconnect negative battery cable. Remove serpentine belt. Remove fan shroud and cooling fan. Using
puller (J-24420-B) remove crank shaft pulley. Remove serpentine belt tensioner. Remove 2 nuts and studs at
front of oil pan, securing front cover to oil pan. Remove remaining bolts securing front cover to block and
remove front cover.
NOTE: To prevent oil leakage, apply RTV sealant to keyway of crankshaft pulley hub
before installing hub.
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Installation
Install front cover and NEW gasket. Tighten front cover bolts to specification. See TORQUE
SPECIFICATIONS table. To complete installation, reverse removal procedure. Tighten nuts and bolts to
specification.
FRONT COVER OIL SEAL
Removal
Disconnect negative battery cable. Remove serpentine drive belt. Remove front crank pulley. See FRONT
COVER. Pry seal from front cover with a large screwdriver or seal puller. DO NOT distort front cover.
NOTE: To prevent oil leakage, apply RTV sealant to keyway of crankshaft pulley hub
before installing hub.
Installation
Apply engine oil to lip of NEW oil seal. Using Seal Install (J-35468), drive seal into front cover. Ensure seal
is fully seated. Apply RTV sealant to crankshaft pulley hub keyway. Position crankshaft pulley hub onto
crankshaft. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See
TORQUE SPECIFICATION table.
TIMING CHAIN & SPROCKETS
NOTE: Before removing timing chain, measure distance between hole in bracket
and unworn surface of tensioner shoe. if distance is more than .3140 (8.000
mm), replace tensioner, chain and sprockets.
Removal
1. Remove timing cover. See FRONT COVER. Align timing marks on camshaft sprocket and
crankshaft sprocket with tabs on chain tensioner. See Fig. 9.
2. Remove timing chain tensioner bolt. Loosen, but DO NOT remove, timing chain tensioner Torx bolt.
Remove camshaft sprocket bolt. Remove camshaft sprocket and timing chain. Remove timing chain
tensioner Torx bolt and tensioner. Using Sprocket Puller (J-22888-20), remove crankshaft sprocket.
Installation
1. Install crankshaft sprocket using Sprocket Installer (J-5590). Ensure crankshaft sprocket is fully seated
against crankshaft. Compress chain tensioner spring, install a cotter pin or nail in hole of chain
tensioner to retain timing chain tensioner shoe and install tensioner onto block. Do not tighten
tensioner bolts at this time. Align timing mark on crankshaft gear with tab on timing chain tensioner.
See Fig. 9.
2. Install camshaft sprocket and timing chain, aligning timing marks on sprocket with tab on timing
chain tensioner. Tighten timing chain tensioner bolts. Install camshaft sprocket bolt and tighten to
specification. See TORQUE SPECIFICATIONS table. Remove cotter pin from chain tensioner.
Lubricate timing chain with oil. To complete installation, reverse removal procedure. Tighten nuts and
bolts to specification. See TORQUE SPECIFICATIONS table.
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Fig. 9: Aligning Timing Marks & Compressing Chain Tensioner

VALVE LIFTERS
Removal
Remove cylinder head. See CYLINDER HEAD. Remove anti-rotation brackets. See Fig. 10. Note location
of lifters for reassembly reference. Remove lifters.
NOTE: Verify use of oversize valve lifters. Oversize valve lifters are identified by a
mark on cylinder block, near lifter bore. If installing new lifter, coat bottom of
lifter with Camshaft Lubricant (GM/1052365) before installation.
Installation
Install lifters in original locations. Tighten Anti-Rotation Bracket bolts to specification. See TORQUE
SPECIFICATIONS table. To complete installation, reverse removal procedure.
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Fig. 10: Identifying Push Rod, Anti-Rotation Bracket & Lifter

CAMSHAFT
NOTE: On Cavalier and Sunfire, engine must be removed from vehicle to replace
camshaft.
Remove engine. See ENGINE. Remove cylinder head. See CYLINDER HEAD. Remove valve lifters,
front cover, timing chain, camshaft sprocket. Remove oil pump drive, camshaft position sensor from right
side of cylinder block and camshaft thrust plate. Remove camshaft. If necessary, use Camshaft Bearing
Remover/Installer (J-33049) to remove camshaft bearings.
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Release fuel system pressure. See FUEL PRESSURE RELIEF. Disconnect negative battery cable. Drain
cooling system. Remove radiator. Evacuate A/C system and remove A/C condenser. Remove cylinder head.
See CYLINDER HEAD. Remove valve lifters and front cover. Remove oil pump drive gear and camshaft
position sensor. Remove camshaft sprocket and timing chain. See TIMING CHAIN. Remove camshaft
thrust plate and camshaft.
Inspection
Measure camshaft journal diameter, lobe lift and runout. Replace camshaft and bearings if not within
specifications. See CAMSHAFT table under ENGINE SPECIFICATIONS.
NOTE: If installing new camshaft, Replace all lifters. Verify use of oversize valve
lifters. Oversize lifters are identified by mark on cylinder block, near lifter
bore.
Installation
Install camshaft bearings (if removed), ensuring oil holes are aligned. Coat camshaft journals and bearings
with a high viscosity oil with zinc (GM/12345501) or equivalent. Install camshaft. Install camshaft thrust
plate. To complete installation, reverse removal procedure.
CRANKSHAFT REAR OIL SEAL
Removal
Remove transmission or transaxle. Remove flexplate/flywheel. For M/T, see appropriate article in
CLUTCHES. For A/T, see appropriate TRANSMISSION REMOVAL & INSTALLATION article in
TRANSMISSION SERVICING. Pry seal from housing, being careful not to damage sealing surface of
crankshaft. Note direction of seal installation.
Installation
1. Coat inner and outer seal surfaces with engine oil. Install seal on mandrel of Seal Installer (J-34686)
until dust lip bottoms against tool collar. See Fig. 11. Align seal installer dowel pin with dowel pin
hole of crankshaft. Install seal installer on crankshaft.
2. Tighten seal installer bolts to 27-62 INCH lbs. (3-7 N.m). Tighten seal installer T-handle until collar
is even with cylinder block. Remove seal installer. To complete installation, reverse removal
procedure. Apply thread locking compound to flexplate/flywheel bolts.
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Fig. 11: Installing Rear Crankshaft Seal

RADIATOR
Removal
1. Disconnect the negative battery cable.

2. Disable the SIR system. Refer to DISABLING & ACTIVATING AIR BAG SYSTEM .
3. Drain the engine coolant.
4. Remove the hood latch support from the radiator upper tie bar.
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Fig. 12: Identifying Hood Latch Support

5. Remove the right and left headlamp assemblies.

6. Remove the radiator upper mounting bolts (1) and the upper radiator mounts (2).
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Fig. 13: Identifying Radiator Upper Mounts

7. Raise the vehicle.

8. Disconnect the SRS forward discriminating sensor harness.
9. Remove the cooling fan assembly. Refer to COOLING FAN CAVALIER (2.2L) .
10. Disconnect the radiator outlet hose from the radiator.
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Fig. 14: Identifying Radiator Outlet Hose

11. Disconnect the lower transmission oil cooler line from the radiator.
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Fig. 15: Identifying Transmission Oil Cooler Lines

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 (1) from the radiator.
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Fig. 16: Identifying Surge Tank Inlet Hose

17. Remove the condenser from the radiator, if equipped. It is not necessary to discharge the A/C System.
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Fig. 17: Identifying A/C System Condenser

18. Remove the radiator assembly from the vehicle.
Installation
CAUTION: Before servicing any electrical component, the ignition key must be in
the OFF or LOCK position and all electrical loads must be OFF, unless
instructed otherwise in these procedures. If a tool or equipment could
easily come in contact with a live exposed electrical terminal, also
disconnect the negative battery cable. Failure to follow these
precautions may cause personal injury and/or damage to the vehicle or
its components.
NOTE: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added
to the system, premature engine, heater core or radiator corrosion may
result. In addition, the engine coolant will require change sooner at 30,000
miles or 24 months.
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1. Install the radiator assembly to the vehicle.

2. Install the condenser to the radiator
Fig. 18: Identifying A/C System Condenser

3. Connect the surge tank overflow hose to the radiator.
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Fig. 19: Identifying Surge Tank Inlet Hose

4. Install the hood latch bracket.

5. Route the SRS forward discriminating sensor harness.
6. Raise the vehicle.
7. Install the cooling fan assembly. Refer to COOLING FAN CAVALIER (2.2L) .
8. Connect the lower transmission oil cooler line to the radiator. Tighten the lower transmission oil
cooler line to 36 Nm (27 lb ft).
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Fig. 20: Identifying Transmission Oil Cooler Lines

9. Connect the radiator outlet hose to the radiator.
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Fig. 21: Identifying Radiator Outlet Hose

10. Connect the forward discriminating sensor harness connector.

11. Lower the vehicle.
12. Connect the radiator inlet hose to the radiator.
13. Connect the upper transmission oil cooler line to the radiator. Tighten the upper transmission oil
cooler line to 36 Nm (27 lb ft).
14. Install the upper radiator mount bolts (1) to the upper tie bar. Tighten the radiator upper mount bolts
to 10 Nm (89 lb in).
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Fig. 22: Identifying Radiator Upper Mounts

15. Install the hood latch support.
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Fig. 23: Identifying Hood Latch Support

16. Install the right and the left headlamp assemblies.

17. Install and adjust the hood latch assembly.
18. Refill the cooling system.
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19. Enable the SIR system. Refer to DISABLING & ACTIVATING AIR BAG SYSTEM .
20. Connect the negative battery cable. Tighten the negative battery cable bolt to 15 Nm (11 lb ft).
21. Start the engine. After the engine reaches normal operating temperature, check for coolant leaks.
THERMOSTAT
CAUTION: Before servicing any electrical component, the ignition key must be in
the OFF or LOCK position and all electrical loads must be OFF, unless
instructed otherwise in these procedures. If a tool or equipment could
easily come in contact with a live exposed electrical terminal, also
disconnect the negative battery cable. Failure to follow these
precautions may cause personal injury and/or damage to the vehicle or
its components.
NOTE: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added
to the system, premature engine, heater core or radiator corrosion may
result. In addition, the engine coolant will require change sooner at 30,000
miles or 24 months.
Removal
1. Disconnect the negative battery cable. Park the vehicle on a level surface.
2. When the engine is cool, remove the surge tank cap and slowly rotate the surge tank cap
counterclockwise about a quarter turn and then stop. Wait until any residual pressure is relieved.
Residual pressure is indicated by a hissing sound. After all hissing stops, continue to rotate the surge
tank cap counterclockwise until the cap is removed.
CAUTION: For procedures requiring the cooling system to be partially

drained, opening the radiator drain valve should provide sufficient
draining. No further actions should be necessary.
3. Use a 1/4" square drive or a 3/16" hex drive in order to open the radiator drain valve. The radiator
drain valve is located at the bottom of the radiator tank.
4. Remove the engine block drain plug. Allow the coolant to drain completely. Inspect the drained
coolant. Flush the cooling system if the coolant is discolored. Continue with the filling procedure if
the coolant appears normal.
5. Remove the radiator coolant outlet pipe attaching bolts. See Fig. 24. Remove the coolant outlet.
Remove the thermostat. Clean the mating surfaces of the radiator outlet and the radiator outlet pipe.
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Fig. 24: Removing/Installing Thermostat

Installation
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
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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.
Install the coolant outlet. Install the coolant outlet attaching bolts. See Fig. 24. Tighten bolts to specification.
See TORQUE SPECIFICATIONS. Refill the engine coolant. Connect the negative battery cable. Inspect
for leaks.
WATER PUMP
Disconnect negative battery cable. Drain cooling system. Loosen water pump pulley bolts. Remove
serpentine drive belt. Remove water pump pulley. Remove surge tank hose. Remove water pump gasket.
Disconnect negative battery cable. Drain cooling system. Remove fan shroud and loosen water pump pulley
bolts. Remove serpentine drive belt. Remove cooling fan and remove water pump pulley. Remove water
pump gasket.
Installation
To install, reverse removal procedure. Use NEW gasket. Fill cooling system.
OIL PAN
Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove engine
splash shield. Remove starter and support bracket and set starter aside. Remove flywheel/converter cover
bolts and remove cover. Remove front engine mount strut bracket. Drain crankcase. Remove oil pan bolts
and oil pan.
Remove engine from vehicle. See ENGINE. Remove oil pan bolts and oil pan.
Installation
Apply a 1/8" (3 mm) bead of RTV sealant to oil pan side sealing flanges, to front of oil pan where it contacts
front cover and to the ears of NEW oil pan rear seal. Install seal onto bottom of rear main bearing cap.
Install oil pan. To complete installation, reverse removal procedure. Tighten oil pan retaining bolts to
specification. See TORQUE SPECIFICATIONS table.
OVERHAUL
CYLINDER HEAD
Gasket Surfaces
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If warpage of head gasket surface or manifold surfaces exceeds specification, resurface or replace cylinder
head as necessary. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. DO NOT remove
more than .010 (.25 mm) material from head gasket surface.
Valve Springs
If any valve spring free length, out-of-square, or pressure is not within specification, replace valve spring(s).
See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
Valve Stem Oil Seals
If installing oversize valves, use oversize seals. Ensure seal is fully seated on guide. Intake and exhaust seals
are different.
Valve Guides
If oil clearance exceeds specification, ream valve guides for .0394 (1.000 mm) oversize valves. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. DO NOT knurl valve guides.
Valve Seats
If valve seat runout and width are not within specification, grind valve seat or replace cylinder head as
necessary. If valve seat is ground, it may be necessary to shim the valve spring in order to obtain proper
spring installed height. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
Valves
Machine valve face if rough. If valve head margin is not within specification, replace valve. See VALVES
& VALVE SPRINGS table under ENGINE SPECIFICATIONS.
Valve Seat Correction Angles
If seat contact is too close to margin, machine seat with a 30-degree stone. If seat contact is too close to
stem, machine seat with a 45-degree stone. If seat is too narrow, widen it with a 45-degree stone. If seat is
too wide, narrow it with a 60-degree stone.
CYLINDER BLOCK ASSEMBLY
NOTE: Before disassembly, mark all parts for reassembly reference.
Piston & Assembly
Ensure bump on connecting rod on top of large end where it forms the connecting rod beam faces away
from mark on top of piston. Install piston with mark on top of piston toward front of engine.
Fitting Pistons
Measure cylinder bore diameter at center of bore. Measure piston diameter at 90-degree angle to piston
pin .4" (10 mm) above bottom of piston skirt. Determine piston clearance. If piston clearance is not within
specification, machine cylinder bore and/or install oversize piston as necessary. See PISTONS, PINS &
RINGS and CYLINDER BLOCK tables under ENGINE SPECIFICATIONS.
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Piston Rings
Measure piston ring end gap and side clearance. If end gap and side clearance are not within specification,
replace piston rings and/or piston as necessary. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS. Install piston rings with a piston ring installer in order to not damage rings. Install first
ring with either side up. Install second ring with identification mark on ring land facing top of piston.
Properly position ring end gaps around circumference of piston. See Fig. 25.
Rod Bearings
If rod bearing oil clearance is not within specification, machine crankshaft rod bearing journals and install
undersize bearings. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under
ENGINE SPECIFICATIONS.
Crankshaft & Main Bearings
If crankshaft main bearing oil clearance, out-of-round or taper is not within specification, machine
crankshaft main bearing journals and install undersize bearings. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
Thrust Bearing
Thrust bearing is part of main bearing No. 4. Pry crankshaft toward rear of engine. Measure clearance
between thrust bearing face and crankshaft. If clearance is not within specification, replace thrust bearing
and/or crankshaft.
Deck Surface Warpage
If deck surface warpage exceeds specification, machine or replace cylinder block. DO NOT remove more
than .010 (.25 mm) material from deck surface.
Valve Lifter Bores
Oversize valve lifters are available to compensate for excessive clearance between lifter and bore. Oversize
lifter is indicated on cylinder block, near lifter bore.
AUTOMOTRIZ TIPO
Fig. 25: Positioning Piston Ring End Gaps

ENGINE OILING
ENGINE LUBRICATION SYSTEM
A camshaft-driven, gear-type oil pump is mounted at bottom of cylinder block and is accessible with oil pan
removed. Oil pump supplies pressurized oil to internal passages of cylinder block. Internal passages
intersect with hydraulic valve lifter bosses where oil flows to main and camshaft bearings and lifters. See
Fig. 26.
Crankcase Capacity
Engine oil capacity is about 4 qts. (3.8L) without oil filter change. When changing oil filter, add more oil if
necessary.
Oil Pressure
Normal oil pressure is 56 psi (3.9 kg/cm2 ) at 3000 RPM.
AUTOMOTRIZ TIPO
Fig. 26: Cross-Sectional View Of Engine Oil Circuit (Typical)

OIL PUMP
WARNING: Pressure regulator valve spring is under pressure. Use caution when
removing retaining pit to prevent bodily injury.
AUTOMOTRIZ TIPO
Removal & Disassembly
Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove bolt securing oil pump to
rear main bearing cap. Remove oil pump and extension shaft. Remove extension shaft and retainer from oil
pump. Disassemble oil pump. DO NOT remove pick-up tube unless loose or broken.
Inspection
1. Replace extension shaft retainer if cracked. Inspect components for damage. Measure depth and
diameter of gear housing. Measure gear diameter and gear length. Measure gear lash (clearance
between tip of gear teeth of both gears). Measure gear side clearance (clearance between tip of gear
tooth and housing).
2. Using straightedge and feeler gauge, measure gear end clearance (clearance between cover plate and
gear). Determine clearance between pressure regulator valve and bore. If clearances are not within
specification, replace components as necessary. See OIL PUMP SPECIFICATIONS table.
CAUTION: Before installing gears, pack oil pump cavities with petroleum jelly to
prime pump. Use only original equipment gaskets when assembling oil
pump, as gasket thickness is critical. Pick-up tube must be replaced if
removed.
Reassembly & Installation
To reassemble, reverse disassembly procedure. If pick-up tube was removed, apply Sealant (1050026) to
MEW tube before installing it into oil pump. Install pick-up tube using Tube Installer (J-8369). To keep
extension shaft retainer from cracking, heat it in hot water before installing it onto oil pump. To install,
reverse removal procedure. Tighten oil pump retaining bolt to specification. See TORQUE
SPECIFICATIONS.
OIL PUMP SPECIFICATIONS

Application In. (mm)
Gear
Diameter 1.498-1.500 (38.05-38.10)
End Clearance .002-.007 (,05-.18)
Lash .004-.008 (.10-.20)
Length 1.199-1.200 (30.45-30-48)
Side Clearance .0015-.0040 (.038-.102)
Gear Housing
Depth 1.195-1.198 (30.36-30.44)
Diameter 1.503-1.506 (38.18-38.25)
Valve-To-Bore Clearance .0015-.0035 (.038-.089)
AUTOMOTRIZ TIPO
Fig. 27: Tightening Engine Mounts (Cavalier & Sunfire)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
AUTOMOTRIZ TIPO
A/C Compressor Bracket-To-Engine Bolts 67 (91)

Camshaft Sprocket Bolts 96 (130)
Connecting Rod Nuts 38 (52)
Crankshaft Pulley & Hub-To-Crankshaft Bolts 77 (104)
Crankshaft Pulley-To-Hub Bolts 37 (50)
Cylinder Head Bolts (1)
Step 1
Head Bolts A 46 (62)
Head Bolts B 43 (58)
Step 2 Additional 90 Degrees
Engine Mounts
Cavalier & Sunfire
Mount Strut Bolts
Step 1 74 (100)
Mount Strut Bracket Bolts
Front 49 (68)
Rear 55 (75)
Mount Assembly Nuts 33 (45)
Mount Assembly-to-Body Nuts 49 (68)
Mount Assembly-to-Accessory Bracket Bolts
Step 1 44 (60)
S10 Pickup & Sonoma
Mount-To-Bracket Nuts 39 (53)
Mount-To-Frame Bolts 38 (51)
Exhaust Manifold Nuts
Cavalier & Sunfire 37 (50)
S10 Pickup & Sonoma 22 (30)
Exhaust Pipe-To-Manifold Nuts 18 (24)
Flexplate/Flywheel-To-Crankshaft Bolts (3) 55 (75)
Intake Manifold
Lower Manifold-To-Cylinder Head Nuts (2) 24 (33)
Upper Manifold-To-Lower Manifold Bolts 22 (30)
Main Bearing Cap Bolts 70 (95)
Oil Pump Bolts 32 (43)
Oil Pump Drive Bolts 18 (24)
Oxygen Sensor 31 (42)
Rocker Arm Nuts 22 (30)
Serpentine Bolt Tensioner Pulley Bolts 37 (50)
Timing Chain Tensioner Bolts 18 (24)
Water Pump Bolts 18 (24)
Water Pump Inlet 18 (24)
AUTOMOTRIZ TIPO
INCH Lbs. (N.m)

Anti-Rotation Bracket Bolts 97 (11)
Camshaft Thrust Plate Bolts 106 (12)
Front Cover Bolts 97 (11)
Oil Pan Nuts/Bolts 89 (10)
Oil Pump Cover Bolts 89 (10)
Thermostat 124 (14)
Valve Cover Bolts 89 (10)
(1) Tighten in sequence. See Fig. 8.
(2) Tighten in sequence. See Fig. 7.

(3) Apply thread locking compound to bolts.
ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Specification
Displacement 134 Cu. In. (2.2L)
Bore 3.5000" (89.000 mm)
Stroke 3.4600" (88.000 mm)
Compression Ratio 9.0:1
Fuel System MFI
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

Crankshaft End Play .0020-.0070 (.050-.180)
Main Bearings
Journal Diameter 2.4945-2.4954 (63.360-
63.384)
Journal Out-Of-Round .0002 (.005)
Journal Taper .0002 (.005)
Oil Clearance .0006-.0019 (.015-.047)
Connecting Rod Bearings
Journal Diameter 1.9983-1.9994 (50.758-
50.784)
Journal Out-Of-Round .0002 (.005)
Journal Taper .0002 (.005)
Oil Clearance .0010-.0031 (.025-.079)
CONNECTING RODS SPECIFICATIONS

Maximum Bend (1)
Maximum Twist (1)
Side Play .004-.015 (.10-.38)

AUTOMOTRIZ TIPO
(1) Replace rod if any bend or twist exists.
PISTONS, PINS & RINGS SPECIFICATIONS

Pistons
Clearance .0006-.0018 (.015-.045)
Pins
Diameter .8000-.8002 (20.320-20.325)
Piston Fit .0004-.0009 (.010-.022)
Rod Fit .0010-.0017 (.025-.045)
Rings
No. 1 & 2
End Gap .010-.020 (.25-.50)
Side Clearance .002-.003 (.05-.08)
No. 3 (Oil)
End Gap .010-.050 (.25-1.27)
Side Clearance .002-.008 (.05-.21)
CYLINDER BLOCK SPECIFICATIONS

Cylinder Bore
Standard Diameter 3.5036-3.5043 (88.991-
89.009)
Maximum Taper .0005 (.013)
Maximum Out-Of-Round .0005 (.013)
Maximum Deck Warpage (1)
(1) If more than.0100" (.250 mm) material must be removed from original surface of deck, replace
cylinder block.
VALVES & VALVE SPRINGS SPECIFICATIONS

Valves
Face Angle 45°
Head Margin (Minimum) .0310" (.800 mm)
Face Runout (Maximum) .00120" (.0300 mm)
Valve Springs
Free Length 1.9400" (49.500 mm)
Out-Of-Square .6300" (1.600 mm)
Lbs. @ In. (kg @ mm)
Pressure (Minimum)
Valve Closed 75 @ 1.71 (34 @ 43.4)
Valve Open 220 @ 1.28 (100 @ 32.5)
CYLINDER HEAD SPECIFICATIONS

AUTOMOTRIZ TIPO
Maximum Warpage (1) .004" (.10 mm)
Valve Seats
Intake Valve
Seat Angle 46°
Seat Width .049-.059" (1.25-1.50
mm)
Seat Runout (Maximum) .002" (.05 mm)
Exhaust Valve
Seat Angle 46°
Seat Width .063-.075" (1.60-1.91
mm)
Seat Runout (Maximum) .002" (.05 mm)
Valve Guides
Intake Valve Stem-To-Guide Oil Clearance .0010-.0027" (.025-.069
mm)
Exhaust Valve Stem-To-Guide Oil Clearance .0014-.0032" (.035-.081
mm)
(1) If more than .010" (.25 mm) material must be removed from original surface of cylinder head,
replace cylinder head.
CAMSHAFT SPECIFICATIONS
Journal Diameter 1.868-1.8693 (47.45-47.48)
Lobe Lift
Intake .2878 (7.309)
Exhaust .2877 (7.307)
Oil Clearance .0010-.0039 (.026-.101)
AUTOMOTRIZ TIPO

Cavalier 2.2

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Cavalier 2.2

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1998 Chevrolet Cavalier

1998-99 ENGINES 2.2L 4-Cylinder

Fig. 1: Locating Engine Partial VIN

Engine is equipped with non-adjustable hydraulic valve lifters.

NOTE: To trouble shoot engine mechanical components, see appropriate table in

REMOVAL & INSTALLATION

CAUTION: When battery is disconnected, vehicle computer and memory systems

J 28467-360 Engine Support Fixture

1. Disconnect the negative battery cable.

Fig. 2: Coolant Recovery Tank Bolt

Fig. 3: Engine Mount Assembly And Drive Belt Tensioner Bracket

Fig. 4: Engine Mount Assembly And Drive Belt Tensioner Bracket

1. Install the engine mount assembly

(44 lb ft) + 90 degrees.

Fig. 5: Coolant Recovery Tank Bolt

5. Install the coolant recovery tank.

FUEL PRESSURE RELIEF

Removal & Installation (Cavalier & Sunfire)

Removal & Installation (S10 Pickup & Sonoma)

Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table.

Fig. 6: Removing Crossmember Assembly

Removal (Cavalier & Sunfire)

Removal (S10 Pickup & Sonoma)

Fig. 7: Intake Manifold Tightening Sequence

Removal (Cavalier & Sunfire)

Removal (S10 Pickup & Sonoma)

Removal (Cavalier & Sunfire)

Removal (S10 Pickup & Sonoma)

Fig. 8: Cylinder Head Bolt Tightening Sequence

Removal (Cavalier & Sunfire)

Removal (S10 Pickup & Sonoma)

FRONT COVER OIL SEAL

TIMING CHAIN & SPROCKETS

Fig. 9: Aligning Timing Marks & Compressing Chain Tensioner

Fig. 10: Identifying Push Rod, Anti-Rotation Bracket & Lifter

Removal (Cavalier & Sunfire)

Removal (S10 Pickup & Sonoma)

CRANKSHAFT REAR OIL SEAL

Fig. 11: Installing Rear Crankshaft Seal

1. Disconnect the negative battery cable.

Fig. 12: Identifying Hood Latch Support

5. Remove the right and left headlamp assemblies.

Fig. 13: Identifying Radiator Upper Mounts

7. Raise the vehicle.

Fig. 14: Identifying Radiator Outlet Hose

Fig. 15: Identifying Transmission Oil Cooler Lines

12. Lower the vehicle.

Fig. 16: Identifying Surge Tank Inlet Hose

Fig. 17: Identifying A/C System Condenser

18. Remove the radiator assembly from the vehicle.

1. Install the radiator assembly to the vehicle.

Fig. 18: Identifying A/C System Condenser

3. Connect the surge tank overflow hose to the radiator.

Fig. 19: Identifying Surge Tank Inlet Hose

4. Install the hood latch bracket.

Fig. 20: Identifying Transmission Oil Cooler Lines

9. Connect the radiator outlet hose to the radiator.

Fig. 21: Identifying Radiator Outlet Hose

10. Connect the forward discriminating sensor harness connector.

Fig. 22: Identifying Radiator Upper Mounts

15. Install the hood latch support.

Fig. 23: Identifying Hood Latch Support

16. Install the right and the left headlamp assemblies.