2001 Chevrolet Cavalier

2001 Chevrolet Cavalier
58
Table of Contents
Product Information ............................ ers RES ree, eee RER 1
Top-Selling Chevrolet Cavalier Still A Leader In 2001 cer arer rec erecr ecrans 1
Cavalier Model [email protected] .…….….…...……….……..…….……criceriserranearaeraranerranarr rare ane r rene rene eee eee eee eee een a 1
Cavalier POWertrainS……...……..……..……….……….…rrcrceerranererrarrranrr crane rence era eee eee eee reee. 1
Cavalier Standard Features ............................eeei in eee eee, anrenenenenen nene rene 1
Cavalier Brakes And Suspension ......................... 0... eee earn eee nenes nnnreenocenercean cen reee eee. 1
Cavalier Wheels And Tires ........................ 0.0 e Ree erre rare tree recaen eateerenr ee reee ree reee. 2
Special Cavalier Bi-Fuel Package ............................ mn ren Der ere reee enen cenar eea career eee rene reneeos 2
Brand Identity.....................................eeeeeene eee eee eee eee eee eee setae eee seer eee eee cerrara eee renes 2
New FOF 20070... A A eee, 2
Interior ............................remeem eee ener errar renererereerar reee rrreen rrenrrarereeanecearantec acera raene reee ranas 2
(1 TT e eee e eee ease seer ee eses see eeee seen eens seen e eee, 2
Vehicle OVErVIEW …..….…..…..….............…....….…nccrasrcrrerrerrrrancrrarerranerr race raner rare eee esses essen sees sense sees eee. 3
Models... Kernen reece ————— nenneonnnnenenennene renace. rere eterna aes 3
Special/Fleet Packages …………………….….……………….…….….……...….……… eee rer e re EEE BER EEEREERR RER RER RER RR RERR EEE ERR EEE ное. 3
Bi-Fuel Cavalier Sedan (interim availability) cocsseneccec canne aocsrececceraece cc anse aaa a aaa aaa aa aaa eee ania 3
Customer Profile .......... EB ERRRRRREREERE RER E RER RER RER BEER RRRERRERER EEE R RER RR EEG N EEEERRRERERRERERRERERRRRRRRERRE RER EEE RER RR ER RER RER E EEE 3
Coupe and Sedan Buyer Demographiics ........................... e... ener reee 3
Competition ..........................eeeeeeeeeeceraneee reee. inenovaonoarenaaane nana ena neon een ooenenran nene neanaeaniemas ee ———————— 3
Color ANA THM «eee ener ene ener reee rre reee aerea rreaare aereo enece cae ene reeee rear eres 4
Exterior Colors...........................eeenrrec ener nene eee er errar ener area rerereaiearaceeere canterano ae reee 4
Interior Colors eenerconecenenenen aran eenaarr re nnrenaraennrrenaareneaneeneace ao rnenareneneeonecen acer nenoeer entrena nreneareenararnarreeenareneeecememe 4
ENGINES cece eee eee eee eee eee eee ee ee eee area renee eee EEE er ——————— 4
2200 L4 SFI and 2.4 Liter Twin Cam L4 Engines ......................... 20... er c rare crane ancre 4
Transmissions......................eeeerre eee OS 5
4T40-E 4-Speed Electronic Automatic Transmission pnnrecarenrareceneaeacenacaareneneenaee sec a are nan e ane nana ea a ec ane 0 ner 5
S-Speed Manual TrANSMISSION ..…......…..……..rrrrerresrerrasnerrrrratance ree reee ee ae 5
SUSPENSION ….…..............ccrrereercrrranereransenranerenanerrracrraaner aan ice rene ea ranen ana eeneneeeneeaée eee a ana a 5
Front Suspension ……….…….…….…….…….…………….….……. e eonnanenaronrercaerenoe area neacananananenananeeareaeee e eearrenenarenanarenaanea ree erencan avec. 5
Rear Suspension ...................... ER ieee PT Nerinannon nena enarenenener arena nenee na nnanenaananananen меннее en
SÉCCIING esses ete a tebe ees eases ees ae eset eases ees ee en en ee eees 5
BrAKES are nene nine nee ere ree ren erre rD e recaen ere eeeeceeeeeeeereneenenes FR ree 5
Wheels and TireS ernennen EEE RER eee eee eee eee eee eee eee eee esas ease eases eee essen sees eens eee eee 6
Wheels ............................. TO enieoerenoerrnenenrecane eee acen ancen ener nanece nenes 6
e L.........…………eecccccrrereceerrecerranserrenrannneererenarerenaranenrarenanee ee ra naaae cena rence ana 6
Feature Availability….….......….................…..…………erccssrrearerrareranerrranersrancr rene caderanerenee rene eee een anna reneeees 7
Specifications .....................................e.ee_ececcee eee. pererrnenannnanenenenereneeee rear trece een nena sans eee reer rere ——— 9
Engine Specifications............... O errr ——————— etree arene ——————— 9
Transmission Specifications ............................... eee e eee eee eee eee eee eee eee, ere ——————————— 9
Steering SPECIfICAtIONS ............oo ieee eee eee ee eee rreeer aa raen acera ererea rene. barneananoocen eee 10
Brake Specifications ...........................en ne ran rare rare reee reee eaenerne reee reee reas EEE RE 10
Dimensions .........................eeeeeeee eee rare e eneDe. Deneocenenerneaonen ener area rene ne erere ane e aan ee aa nana nsc enr accent 11
Exterior ......................... Eee eee eee eaten rre nacen erenaran racer acenacenacenacenorenereearen eee errearenere erre arena aremenes 11
Interior ...........................=ieemeee nen nene anna rerenereenerrernene arar rerrreer reee reee ea reee eeos 11
Capacities and Weights...........................ereee e e ener EEE maneseree rene een ssene nee reer cena eee ane eee n nana eee nana nee 11
Trailer een er ene. 11
Cavalier History .….…..............…...…..........………cressreasrranerracerarrransreaneeranee anee rene rare ecran ere eee eee een 12
Miscellaneous Information ....................... eee. 13
Technical Product Information ........................... ee een ere rc casser rare Direneeeenrnenen enana area nece nara. 13
Vehicle Classification ............................ een rana eee eee eee eee eee eee eee eee eee eee ee eee eens 13
Assembly Plant Locations ................ PT eres DP ee 13°
Ргате..........нненнннееенннненееененнннн eee eee aera eerie ra————— eee eee reer ————————————— 13
Chassis Layout........................e..eeeereeni eee eee eee eee eee eee eee eee eee eee eee eee e ee essen enieinanenees 13
Body Material ..............................einieae e ener RER rene nereeaarrrrrrrreeree errar e eenrenenenanereneeaneacen eran nenes 13
Affinity Relationships ............................ euricarronenacenmeceneeceanarenece nacen ecen ere naeren reee arena ae ener rrene. ——— 13
Recreational Towing ......................—.... nnrrnenoneren nen neneecacecenacaa ran ecaaea aaron rerereeeenenon e erecerereeeeeoeerenrrreee 13
Recreational towing highlights and restrictions for the Cavalier: ................................ eee 13
Vehicle Identification... Danerenvenarenenebacacarenenenacane a nananenanananarone rodear nene ear. 14
Vehicle Identification Number (VIN)........................... eee eee eee eee eee essen ene, eerereeeerean. 14
VIN Derivative .......................eenn eii e ree ee eee eoinecenerenneneenTenen ene neaane nee anareeneaeaceeeearenenec Tara nana 15
Label Certification rer EEE Зенненеееенннненннннннннненннннннненеенннннееынннненненннные 16
Tire Placard.......................enenninninene nen ener enero nee rneneeee ener nee ener iereeneneneeTerereeceeLene reee 17
- Service Parts Identification Label (SPID)............................ nenneneaoreceneneenenaererteURe RR e eUaa recen eneneneees PT 17
Engine ID and VIN Derivative Location ..............................eee ene e en rn reee eee errar evener reee mar aereos 18
2.2 L VIN 4 Engine ID Location .................. nenes PA erieieneeane e nene nene renace nenaneeneeeees 18
2.4 VIN T Engine ID Location...........................eee eee reee eee einer reee reeneees ATT eee 18
Transmission ID and VIN Derivative Location .............................. eee ree rene raereneee eee acen enees 19
3140 Transmission ID Location ............................ eee ene ener erre nera nera rer reee rrreecernaereceee eones 19
4T40E Transmission ID Location ……………….……………….…….……ecrrrenenennnenenmenmnennnnennnnnnnnnnnnmnemn“annndtÜd
Automatic Transmission ID Nameplate………….……...…….…..….….….…rrrrerrerrrarsereneererrare ce renn ner anne renee vues 21
VIN Derivative Location 4T40/4T45-E.............……..……rcrrrreerranrranreranceanrrae carre rare anee eee eee 22
Getrag 5T45-E Transmission VIN Location, M86 besaeeereree sera race sace senc ana ce rence e name canne nano seen mean a nane nana e Gaec eee te 22
RPO Code List...........................eemeieeencee nene Deere eee ree rene eerecereeneraen ener erer reee reee rear annee 23
Technical INFOrmation ................. ene eee eneeneen ener ren reee 27
Maintenance and Lubrication.......................——.—.. eee nen eenen enema ee ———————— SA era ss 27
Capacities - Approximate Fluid srrrieeraeecenan ecran ce nre naar en nare ren aaren nana cena n cannes seacesseeccnenecce ns 27
Tire Inflation Pressure Specifications TT OUUORR 27
Maintenance ltems.............. reer ————————— еенененеее. enicanmnannnnnbanaanaa. A are e er EEE nrcecinennenenena 27
Fluid and Lubricant Recommendations .................... Nerenaneonareacaneacenenenececenene eanncorneneeene reee reee anne arenas 28
Tire and Wheel Runout Specifications............................ eee reee reee rie riera raee renace tarea een, 29
Tire and Wheel Assembly - Lateral and Radial.................. noninoonanenenareanaanenerenenecanannarenivanananoreacenoarreeeeee 29
Wheel, Aluminum ............................r.eeeeceene reee eee rere —— ennanene nene ee reee n eee 29
Wheel, Steel..................................ennee enn near lane rernees O
- Wheel Hub/Axle Flange - Guideline ................................. emir nee. сене erate ————————————— 29
Wheel Stud - Guideline cc. e eee eee eee een ane ca aan 29
Descriptions and Operations .................................. 0 ee Re ee reee eeer reee eenereeree earn 30
Power Steering System Description and Operation w/o Electro-Hydraulic Steering......................... 30
Steering Wheel and Column - Standard Description and Operation ............................................ .....JO
0 nen e eee eee eee eee eee eee esas ease eee esas ease eenenees PT 31
Vehicle Security ...........................eeeerene eee eee eee eee eee eee e eee eeer arena reeee errar rereneca recrean eaereraneeeenes 31
Driver Convenience .......... eer rere ern ——————— rere ————— FT 31
Driver Safety eee eae, eee reer areata ener eae 31
Suspension Description and Operation... eens nee 31
FrONt SUSPENSION... eee eee eee eee eee eee eee eee eee eee eee, TR 31
Rear Suspension ............... ee... ener renace. Dernecanenereanaseaneacenecen veneran acen an en sen cena acces 32
Wheels and Tires…….…........……….rrrrrrrrcnres enonerenenenicanenetenenerenre anne RT nrereRenereneRe nace ne ercer eneeen area en erreee ene. 32
General Description …..….….……..….….…..…….…ecriierereneenmenmennnnnnnentnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnmnnnnnmnn 32
Tread Wear Indicators Description............................. ene SR PU EE ен Заннннннннннные 33
Metric Wheel Nuts and Bolts Description............. RTE ee reas errr 33
Tire Inflation DESCriptioNn.….…………………………….……rrrereeerecerecererererererreserrer reve verve verre eee 33
P-Metric Sized Tires Description ere RFF EEE 35
Braking System Description and Operation ........................ A er TT e o
Hydraulic Brake System Description and Operation ............................. eee ee Rene reee 35
System Component Description... eee eee eee ener 35
System Operation….….….….…..….….……......sseeserrrrrrrrananneerrranaaaan eee eee rer e een enr nana ean 36
Brake Assist System Description and Operation ............................. eee eee re eee eee eas 36
System Component Description penercanernen eninernenerenenereceeneacareaneneeceeeaceneacecen acera aneren ene renenerrenerenea arena. 36
Зуз!ет O/0/- | ¡(o TD 36
Disc Brake System Description and Operation... e ene nene rre enerreeeeeees 37
System Component Description ....................e. сене RR ERR ER ERRR EEE ERRRERREERREERR RR ER RER 37
“System Operation…..….…..........….….…....…secrrerrenseneneerransenrarrasnae ner rer rananaa ner r caen eee nanaane een e nn ananas 37
Drum Brake System Description and Operation...............................600 0 ee e eee rene. 37.
System Component Description.................................. eee. reee rr reinan erre reeeeererereeeeaaeeceneeeeeeeeeeees 37
SENO |¡(] eee ee eee eee ee eee eases eases eseeeeerae eases seassssreenees 38
Park Brake System Description and Operation ............................eeee 6.0. reee nera eeerrreeeeeems 38
System Component Description....................... FESTUS eres 38
ES) CEO | ¡(| a O eee encnn nana ananas 38
ABS Description and Operation ............... Nnneanirennarronerenaneneeen ear eenenaaneeaceneeenacaceneenereee area nacen enneene naar enano. 39
Antilock Brake System mes laanenaierenenee naa eno e ener enn enenernen nenes pnnninneneneeenes 39
Engine Description and Operation ..................................e.e ee ee een reee reneneree erroneo. 40
Engine Mechanical — 2.2 ...........….…………rrrrrerrersansaneennrerrannareneerr rss aa ranaaaaana een e rare eee ee nan rene aanaaaana een 40
General Data ………........…......…...….……rrrreerensassensraansrnranseras aan RER R ER ER RER ER RR RR EEE R EEE EEE A 40
Fastener Tightening Specifications ………....…….......….….….….…errerrenmmenennnnnmnnnnnennnnnnnmnnnnennnnnnn*nnn*n*n*mnn 40
Drive Belt System Description ..…....…..…..….………..…..….………iererrerssneeemnnnmnnmnnnen er ranaeraranaase encres rraae ecrans 41
Engine Mechanical — 2.4L ....... ooo eee eee eee eee eee eee eee eee ease eee ee eee eee eee e seen eee ee enon, 42
General Data........................eeeicen eee eenenecroneneocenearenanereaneanenneneaoeaeee nacen arena neren reee 42
Fastener Tightening Specifications ................................ ree eee nene reee. nenennanonenenenene. 42
Engine Cooling ............................. Nnenenoanenene arena ooce ren renaneanananeeneannencenneoceenereeecenneneceneerrenareeenrererenanereen reee. 43
Engine Cooling System Approximate Capacities ................................e. e De erie 43
Fastener Tightening Specifications..............................e...ee eee Renee 43
Cooling System Description and Operation ................................. eenercenarerenaneoceocanereanarenenenenareneaeean nenes 44
Coolant Heater TT O ee ee eee eee eeee eee anes eeene en, 44
Cooling System cei eee a eee eee eee e eee e eee tesa eae eases aaa ee meee ees eeaaasnneaee senses 44
Cooling Cycle ................... peonenea nena eneauana navara rad na raaeno nero r roer rene conan erence mea de rene canevas PT ere venee 44
0707017 10 eee KERRRRERRRRERRRRERRERERERRRERERERRERRREEEEREREEEREERREEREERREERRRRRREERRERERRRELEEEN 45
RAIGEON cee eee eee eee eee eee RER EERR RR ER EEE RER EEE E EEE EEE R RER na aan 45
Pressure Cap... eee nene rare neeeee nnenenearrenenaneceneeceenacenaacee arena nana 45
Coolant Recovery System .........................e.erevreriii iD RI ORI III OI O III RER ener reeenenerevaneeeens 45
Air Baffles and Seals.................................eme eee eee, reer nene 46
Water PUMD ocean eee —————— ns 46
Thermostat ........................eeieecrnenenenen eee ener reienee RER reee nnerereeeera radar eneeree rr rrrire rene ereraeceees 46
e -L0E0./. (- E NO 46
Transmission Oil Cooler.......................... eee. ner eee eee reee ner rene cena renern ener reee. eee 46
Engine Electrical...................................... es O DO 47
Fastener Tightening Specifications... eneocebeoreconeconenonecanane naar eee ema. Nenenenanereneaceneereanen es 47
Battery Usage ……....….…….…..…....….…..……rrrerrererrrerranannerrananaaeerrrrananeeenerannenaan aa enan nana ee nee a aa rae aaa aaa reas eens 47
2.2L ACYI (LINZ, LBM) cee eee eee eee eee eee eee eee eee eee eee eee a eae eens eecicanenene rene. ..AT
2.41 Acyl (LDO) eee eee eee eee eee eee eee eee eee e tea e eee eae ee ——————..aan 47
Generator Usage ......... pennanoanenaronannanencane nena ne nnenmeanaarnanenaarnarteane no nenra nante neaneoaaatarace maana rete neveree amena rre anerreene. 47
Battery Description and Operation ............................... eee ere ne rear rerarerererrrrerrveeeeceeaeeaaaeeeea 48
ala '-E07-/e/-(01] TT eee en nn ananas 49
Cold Cranking Amperage....................... Eee eee eases eee eee ease e een eres snare a ee aneas 49
Circuit Description ................... RE aninannn e ens RS 49
Starting System Description and Operation............................ e e a ere eee ene aerea rerereere. 49
Circuit Description... e nene rien rea ree rraaee eee nera ener eee, eee 50
‘Charging System Description and Operation .............................. ie reee arena eee erario 50
Generator ........................eeeiin nn ner aerea irene rrueeeeea Aeriooaioeneerenareren e reneeneneane eee nenecen er renanerenererenen os 50
Regulator... ee cacsrreree rene rene nca neenensen nana ee nan en annees rhasenasrecs serre sance see e nana anna nee e aan 50
Circuit Description rec e eee eee ee reee eee eee re ———————— 50
Charging System Indicator............................ EEE REN ennriracennonaaceceno ocean renace ereenenoreecene 51
Engine Controls..................................ceee ener eee en ree reee reee rara reee rece rene reneereneree errar eeeeo 51
Engine Controls - 2.2L (LN2) ............................... ee enero evens eee eee aera. 51
Ignition System Specifications ........................ mes een, RE 51
- Fastener Tightening Specifications eee ——— eens 51
Fuel System Specifications ................................eeeee.... O TD 52.
Electronic Ignition (EI) System Description ................................. reee e eee eee een enero 53
Air Intake System Description ........ EEE 54
Engine Controls = 2.4L (LN) ........coiiieeeeeeee eects eee e eee eee ee ees rrr — 55
Ignition System Specifications ................ Внненнннннннсененнооенннме неее сееенннноснннееннненнннннннннннннннеснннне. ..55
Fastener Tightening Specifications ................................ ere EEE eee ————— rere E LEERE 55
Fuel System SpecificationS essen R eee eee eee eee eee eee eee eee eee eee eee ae 56
Electronic Ignition (El) System Description ................................... ener e aerea eee 56
Air Intake System Description ......................................... nenreneneeranenanenenan eee cen ee neceee Neneamananaeneosrenmeneaas 56
Exhaust System ..........................e..220000600 e eee. nenenonearenennenence nera reneneaenane aerea anne eee sense enanos 56
Fastener Tightening Specifications..............................iie ie ee eee eee eee eee eee eee eee eee eee, .56
Exhaust System Description ............................. reee rene ene cessseecee rence n rence nee rene annee een 56
Resonator......................een een rene reee. rector neneceniannanreneorerene recen ranconnenenaneo eeanennanen nenes 57
Catalytic Converter ee eee eee ee eee eee ee eee eee sees sesame esses eee eee 57
MUfflEr ……......….....…....…+crrecrerererrererererrenrenaressenrancenaareaner race rene ee ranr een crane acer eee een aan aa 57
Transmission/Transaxle Description and Operation ........................................ ee eee nee 58
Manual Transmission - M86/M94 Getrag ........................ OTRO 58
_Fastener Tightening Specifications ..........................—........ienee reee Seren rere eres 58
Lubrication Specifications.................................ececeeee neos AA N ERREERERRRERR EEE RRRRRR RR RRR RER RRELERELG 58
Shim Size SpecificationS arena eee. TO 58
Automatic Transmission Shift Lock Control Description and Operation ................................. nenes. 59
Automatic Transaxle - 3T40.......................neeene ener errar reee reeerereereeranea eee aeinee reee reee Зее. 59
Fastener Tightening Specifications ..............................iiice ie er er ee re eee rare reee rene eneecanennnens 59
Transmission General Specifications ................... Dninnnenea nene cenearenenenenenicacrer reee ene nn eee enerenennrereerrrrereceeanes 60
Fluid Capacity Specifications ..................................eree eee arena enaer rene eee errr iea een 61
Range Reference ……….….….….….….….…….….…….….….….……………… e eoeneoceraaanaanananana ne oooanneereaaa oe nneerrecancococanrnnanananaa o ooooeanerenanecenees 61
Shift Speed...........................ereiiein nee eee eee ee eee eee ee eee eee eee aan ee ———————— ..61
- Transmission General Description ..................................eeie e... ninereneoneeneneneanenannacenenerenenece nana os 62
Transmission Component and System Description ................................. reee eee ena eres 63
Automatic Transaxile - 4T40-E/4T45-E............................. eee ee 63
Fastener Tightening Specifications Unit Repair... eerinenorenenen cacon. 63
Transmission General Specifications................................ ein Der De Dee ae eee esses eee, 64
Fluid Capacity Specifications .............................r eee reee e ere eee eee eee, creer 65
Range Reference ………….….….……….……...ienmenenantentenennnnennnnnnnnnnnnnnmnnnnnmnnnnnnnnnnnnnnnnns 66
ES. eee eee eee eee eee eee eee eee ee eee ane eee eee aa 66
Transmission General Description .............................. eee eee eee eee eee eee eee encre eee eee eee 67
Transmission Component and System Description ............ marane sean t a ner ee tease race ee rene ce nan eee en ce n ee sance cena 67
Adapt FUNCtION cee eee eee eee eee eee reere ener eeaeeros 68
CIULCN eee eee eee eee eee eee eee eee eee eee eee FR 68
Fastener Tightening Specifications ........................... eee eee eee eee eee eee eee eee eee, 68
Hydraulic Clutch Description BERR ERE RRR RNS 68
Abbreviations and Meanings..................... ee —— eres RTE |
Conversion - English/Metric e mee rene eee nenes trees |
Equivalents - Decimal and Metric aerea eee e erre erarere reee reos ii
FASIENEIS ..... o.oo eee eee eee eee eee eee eee eee eee sere esses eee eee
Metric Fasteners ers acens OS i
Fastener Strength Identification …………….….…….…….…….…….…ererenenennnnnnennnnnennnnnnnnnnnmnnnn*nn |
Prevailing Torque Fasteners............................. ee. eee eee eee ——— etree eee eee n aera. i
All Metal Prevailing Torque Fasteners ............................ eee eee eee eee eee eee eee. |
Nylon Interface Prevailing Torque Fasteners..............................e. 00 re reee nenes i
Adhesive Coated FaSteNe Sarnen rer EE EEE EEE EE EEG ee ——— rere i
Metric Prevailing Torque Fastener Minimum Torque Development....................... etree ener renee era —————— i
All Metal Prevailing Torque Fasteners .............................. ie ee ee are earn reee TR Ш
Nylon Interface Prevailing Torque Fasteners... es ee e nern ii
English Prevailing Torque Fastener Minimum Torque Development Ds iv
All Metal Prevailing Torque Fasteners .................................. ee rene ee. ereconnenearenee arena nenenacereenenans iv
Nylon Interface Prevailing Torque Fasteners................ eee eres eee, iv
2001 Chevrolet Cavalier Restoration Kit
Product information
Top-Selling Chevrolet Cavalier Still A Leader in 2001
DETROIT — The Chevrolet Cavalier is General Motor’s best-selling passenger car and one of the ten
best-selling cars in the United States. With refinements such as a premium amplified audio system and a
new color added to Cavalier's already impressive list of standard equipment, Cavalier is poised for
another successful year in 2001."Cavalier has been very successful in attracting young buyers to
Chevrolet, due to its standard equipment that even includes four-wheel antilock brakes," says Steve
Wagg, Cavalier brand manager.
Cavalier Model Lineup
For 2001 the Cavalier lineup will include four models: Cavalier Coupe, Cavalier Sedan, Cavalier LS
Sedan and Cavalier Z24 Coupe. |
Cavalier Powertrains
- Cavalier Coupe, Sedan and LS Sedan all come equipped with a proven, efficient and low- maintenance
115-hp 2200 L4 engine with ‘sequential fuel-injection. Optional on the LS sedan, but standard on Z24
Coupe, is a 2.4L Twin Cam L4 engine that cranks out 150-hp and 155 Ib.ft. of torque for spirited
performance and impressive fuel economy.
All Cavaliers, with the exception of the LS sedan, come equipped with an efficient 5- -speed manual Getrag
transmission that is engineered to make shifting smooth and easy. A 4-speed electronically controlled
automatic transmission is standard on the LS Sedan, optional on other Cavalier models. This lightweight
but durable automatic comes with long-life automatic transmission fluid. Included with the automatic is
traction control, a feature not even offered on many cars in the Cavalier's price range, for added stability
when accelerating on slippery roads.
Cavalier Standard Features
One of the reasons Cavalier is so successful is its high level of standard equipment at a reasonable price.
Standard safety and security features include: dual front air bags, brake-transmission interlock on
automatic-equipped cars, Daytime Running Lamps and a PASSlock™ theft-deterrent system. All Cavalier
buyers enjoy standard features such as air conditioning, electric rear window defogger, front bucket
~ seats, a full-folding rear seat and intermittent windshield wipers.
Moving up to the LS sedan and Z24 Coupe, standard features also include cruise control, power door
locks, tilt-steering column, body-side moldings and an upgraded AM/FM stereo radio with CD player and
TheftLock anti-theft system. |
New for 2001, Indigo Blue Metallic is added to the exterior paint palette, while a CD radio is now included
on Base models when the optional Preferred Equipment Group 1SB is ordered. The V11 Sport Package
on the base coupe now includes the new 6-speaker premium amplified audio system with rear-woofer
speakers, rear spoiler and tachometer.
Cavalier Brakes And Suspension
Another standard feature that sets Cavalier apart is front disc/rear drum brakes with four-wheel antilock
brakes (ABS). Standard ABS on all models adds to Cavalier's value because other competitors in this
price range don't offer ABS as a standard feature on all models. It's either an extra cost option or
available only on higher-cost trim levels.
The standard suspension includes MacPherson strut front and trailing twist-beam rear with coil- -over-
shock corners that help provide a smooth ride and excellent driver control.
Page 1
2001 Chevrolet Cavalier Restoration Kit
. Cavalier 224 Coupe boasts a more aggressive suspension befitting its sportier demeanor. The Z24 has
shaped inner-metal bushings on front lower control arms, higher-rate front and rear springs, stiffer shocks
and struts, and a larger front stabilizer bar. This combination helps provide a firm ride, yet sportier feel
and better handling than the base suspension design.
Cavalier Wheels And Tires
Base Cavalier models feature 14-inch wheels and all-season tires to handle a variety of road demands.
The LS Sedan comes with larger 15-inch wheels and all-season touring tires for an even smoother ride.
Full wheel covers are provided on all. In keeping with the sporting nature of the Z24 Coupe, 16- Inch
aluminum wheels with more aggressive P205/55R performance tires are standard.
Special Cavalier Bi-Fuel Package
A special bi-fuel version of the Cavalier is available for both fleet and retail sales. It meets all federal
safety standards and Transitional Low Emission Vehicle (TLEV) standards in all 50 states. The Bi-Fuel
Cavalier Sedan uses the 2200 L4 engine and automatic transmission, but runs on gasoline and
compressed natural gas (CNG). Its fueling system uses the CNG first, for an estimated 160 miles, then
automatically switches over to gasoline, if necessary, for roughly 400 more miles. To accommodate the
added weight of its fuel system, this Cavalier has an upgraded suspension system. Like all Cavaliers, it is
backed by GM's 3-year/36,000-mile No-Deductible Limited Warranty and can be serviced at authorized
GM dealers and facilities throughout the United States.
Brand Identity
The Chevy Cavalier is a smart buy. Look again and see it as one of the great values in its class.* In
addition, Cavalier has an impressive safety package which includes Daytime Running Lamps (DRLs) and
a PASSIock® theft-deterrent system.
* Based on 2000 competitive information and GM segmentation. Excludes other GM vehicles.
New for 2001
Interior
e CD player i Is now included in PEG 1SB on Base Coupe and Sedan and standard on LS Sedan and
Z24 Coupe
e 6-speaker Premium Amplified Audio System with rear-woofer speakers i is optional with the UIC CD
radio and standard with the UPO uplevel CD and cassette dual playback radio
Exterior
e Indigo Blue is a new color
e V1I Sport Package now includes the rear spoiler, tachometer and Premium Amplified Audio System
Page 2
| "2001 Chevrolet Cavalier Restoration Kit:
Vehicle Overview
Models
e Cavalier Coupe
e (Cavalier Sedan
e Cavalier LS Sedan
e Cavalier Z24 Coupe
Special/Fleet Packages
Bi-Fuel Cavalier Sedan (interim availability)
Gasoline and compressed natural gas (CNG) power the Bi-Fuel Cavalier Sedan which was introduced in
1998. lts fueling system uses the CNG first for an estimated 160 miles and then automatically switches to .
gasoline, if necessary, for about 400 miles.* Using a patented Hyperfill device, the CNG system includes
a fuel tank which holds 6.9 gallons gasoline-equivalent @ 3600 psi. This system has undergone
extensive testing and meets federal safety standards and Transitional Low Emission Vehicle (TLEV)
standards in all 50 states. Available for fleet owners and retail sale, the Bi-Fuel Cavalier Sedan is backed
~ by the GM 3-year/36,000-milet New Vehicle Limited Warranty and can be serviced at authorized GM
dealers and facilities throughout the United States. To accommodate the added weight of its fuel system,
this Cavalier has an upgraded suspension system. The Bi-Fuel Cavalier has many of the same standard
items as other Cavalier models, including: a
2200 L4 engine
Automatic transmission
Driver and front-passenger air bags**
Power steering
4-wheel antilock brake system
Stainless-steel exhaust system
* Individual mileage may vary.
{+ Whichever comes fi rst.
** Always use safety belts and proper child restraints, even with air r bags. Children are safer when properly secured i in a rear seat. See the Owner's Manual for more safety
information.
Customer Profile
. Cavalier remains one of the top new-car choices for first-time buyers*. With many standard features, it
offers value to the small-car buyer. It's the kind of car for young-minded people with purchasing savvy
who want a more attractive, quality small vehicle reflecting their sensibility.
* Based on General Motors TCE Buyer Behavior Study — 1999 model year.
Coupe and Sedan Buyer Demographics
Median age: 18-24 Years
~ Median household income: $50,000
Purchaser (male/female): 35%/65%
‘Married: 25%
College graduates: 40%
Competition
e Ford Focus
e Dodge Neon
e Honda Civic
Page 3
2001 Chevrolet Cavalier Restoration Kit
Color and Trim
Exterior Colors
Dark Colorado Green Metallic
Ultra Silver Metallic
Sandrift Metallic*
Bright White
Black
Indigo Blue Metallic
Bright Red
Cayenne Red Metallic
*
Not available on Z24 Coupe.
Interior Colors
e Graphite (includes Red inserts for Z24 models and Teal inserts for LS)
e Neutral | | |
* Medium Gray (LS and Z24 models)
Engines
2200 L4 SFI and 2.4 Liter Twin Cam L4 Engines
Technical Features of the 2200 L4 Engine:
Valvetrain roller rocker arms use roller bearings to reduce friction
Hydraulic roller valve lifters
"Assembled" steel camshaft
Induction system features two resonators and a large-volume air cleaner for
quiet operation
Sequential Fuel Injection (SFI)
Cast-aluminum cylinder head
Torque axis powertrain mount system
Exhaust Gas Recirculation (EGR) system
. Low-maintenance features, including platinum-tip spark plugs and extended-life engine coolant.*
Maintenance needs vary with different uses and driving conditions. See the Owner's Manual for more information.
1
Technical Features of the 2.4 Liter Twin Cam Engine:
Dual overhead camshafts
Cast-aluminum cylinder head
Composite intake manifold
Sequential Fuel Injection (SFI)
Exhaust Gas Recirculation (EGR)
“In-oil-pan" design balance shaft system
Torque axis powertrain mount system
Stainless-steel fuel injectors
Direct-drive power steering pump
Low-maintenance features, including platinum-tip spark plugs and extended-life engine coolant.*
>»
Maintenance needs vary with different uses and driving conditions. See the Owner's Manual for more information.
Page 4
2001 Chevrolet Cavalier Restoration Kit
Transmissions
4T40-E 4-Speed Electronic Automatic Transmission
The 4T40-E is standard on LS Sedan and optional on all other models.
Technical Features of the 4T40-E Transmission:
Fully integrated and synchronized Powertrain Control Module (PCM)
4T40-E is lightweight, contributing to overall fuel efficiency
Chain-transfer two-axis configuration
Special lightweight composite materials
Long-life automatic transmission fluid*
Traction Control is standard with the 4T40-E
*
Maintenance needs vary with different uses and driving conditions. See the Owner's Manual for more information.
5-Speed Manual Transmission
A Getrag 5-speed manual transmission is standard on all Cavalier models except the LS Sedan.
The 5-speed manual transmission and clutch are engineered to make shifting smooth and easy:
e Clutch pedal has a short, efficient travel
e Concentric slave cylinder provides a solid pedal feel and smooth clutch operation
Suspension
Front Suspension
MacPherson strut front suspension with coil spring
e "Progressive-ride" system helps allow precise tuning between the chassis and suspension system
e Level ll Sport Suspension, on Z24, includes shaped inner-metal bushings on front lower control arms,
high rate front and rear springs, and a large stabilizer bar |
e Accurate wheel alignment is provided at all four wheels by using precision equipment during the
manufacturing process. Throughout the vehicle-build process, measurements are taken to help
provide that components affecting final wheel alignments are correct
19mm link-style stabilizer bar for Coupe and Sedan models with LD9 engine
22mm link-style stabilizer bar for Z24
Rear Suspension
e Training tubular control arms with twist-beam axle
"Coil-Over-Shock" design
e 18mm solid stabilizer bar for Z24
Steering
e Power rack-and-pinion for all models
e Steering rack mounted on the front suspension cradle
Brakes
e Power-assisted front disc and rear drum
e Four-wheel ABS
Page 5
2001 Chevrolet Cavalier Restoration Kit
- Wheels and Tires
Wheels
14-inch x 6-inch full wheel cover — standard on Coupe and Sedan models
» 15-inch x 6-inch full wheel cover — standard on LS Sedan and optional on Coupe
+ 15-inch x 6-inch aluminum wheel — optional on Coupe and LS Sedan
* 16-inch x 6-inch aluminum wheels — standard on Z24 Coupe
Tires
P195/70R-14 all-season tires (standard on Coupe and Sedan models)
P195/65R-15 all-season Touring tires (standard on LS Sedan and optional on Cavalier Coupe with
PEG 1SC only)
e P205/55R-16 Performance tires (standard on Z24 4 Coupe)
Compact spare tire
Page 6
2004 Chevrolet Cavalier Restoration Kit
Feature Availability
se
ss
n Electronically Tuned Receiver
ES BR NOS
NOTE: All sound systems feature a
scan.
(ETR
Air bags — driver and front-passenger(1) S S S
Air conditioning — with CFC-free refrigerant S S S
Cruise control O(2)/NA S S
Defogger — rear-window, electric S S S
Door locks — power O(3) O(3) S
Easy entry passenger seat O/NA NA S
Seat — front bucket and full-folding rear S S S
Sunroof — power O/NA NA O
Tilt-WheelTM steering column O(2)/NA S S
Trunk release — mechanical/power O/O(3) S/O(3) NA/S
Instrumentation
— tachometer O/NA S S
— trip odometer ~~ S S S
Windows — power O(2)/NA S
SER RE pe es
.|Daytime Running Lamps
AM/FM stereo Ss NA NA
AM/FM stereo with compact disc player and TheftLock (includes premium O S S
front coaxial speaker)
AM/FM stereo with compact disc and remote cassette players, TheftLock, O O O
speed-compensated volume, auto tone control, and Radio Data System
(RDS) (including Premium Amplified Audio System)
Six-speaker Premium Amplified Audio System with rear-woofer speakers O O O
5. S S
Foglamps NA NA S
Mirrors outside — electric O(2)/NA O(2) S
Moldings — body-side, body-color O(2) - S S-
Mud guards — front | O(2) S NA
Paint — basecoat/clearcoat S S S
Spoiler — rear decklid O(4)/NA О S
Tires
— P195/70R-14 all-season S NA NA
— P195/65R-15 all-season Touring O(2)/NA S NA
— P205/55R-16 all-season Performance NA NA S
Wheel covers
— 14-inch full S NA NA
— 15-inch full O(2)/NA S NA
Wheels
— 15-inch aluminum O/NA O NA
— 16-inch aluminum NA NA S
Wipers — intermittent fixed S NA NA
Wipers — intermittent variable O(2) S S
Page 7
2001 Chevrolet Cavalier Restoration Kit
Brake system — 4-wheel antilock (ABS)
Engine
— 2200 L4 SFI S S NA
— 2.4 Liter Twin Cam L4 SFI NA O S
Exhaust system — stainless-steel S S S
PASSIock® Il theft-deterrent system S S S
¡Remote Keyless Entry (includes power door locks and content theft alarm) O O s
Steering — power rack-and-pinion S S S
Transmission
— 5-speed manual 5 МА S
— 4-speed electronically controlied automatic with Traction Control
Air bags — driver and front-passenger(1)
Brake system — 4-wheel antilock (ABS)
Brake/transmission shift interlock (auto trans.)
Clutch/starter interlock switch (manual trans.)
Daytime Running Lamps
PASSIockO II theft-deterrent system
00100100 |1 0100 | 0
0 |0 |0 |0 | 0 | 0
Remote Keyless Entry with content theft alarm
О
5
S — Standard. O — Optional (some options may be available only as part of a Preferred Equipment Group). NA —
Not available. (1) Always use safety belts and proper child restraints, even with air bags. Children are safer when
properly secured in a rear seat. See the Owner's Manual for more safety information. (2) Requires optional PEG.
(3) Requires optional PEG 1SD on Coupe and included with optional Remote Keyless Entry on Sedan and LS
Sedan. (4) Included with optional Sport Package.
Page 8
2001 Chevrolet Cavalier Restoration Kit
Specifications
RPO LN2 LD9
Displacement (liters/cu. in.) 2.2/134 2.4/146
Bore x stroke (in.) 3.50 x 3.46 3.54 x 3.70
Bore x stroke (mm) 89.0 x 88.0 90.0 x 94.0
Compression ratio 9.0:1 9.7:1
Cylinder block material cast-iron cast-iron
{Cylinder head material
cast-aluminum
cast-aluminum
Valvetrain configuration OHV - DOHC
Valves per cylinder 2 4
Induction system SFI SFI
Ignition system electronic electronic
Lifters hydraulic roller hydraulic
Cam drive chain chain
Coolant capacity (quarts/liters) 9.6/9.1 10.0/9.4
Oil capacity (quarts/liters) 4.0/3.8 4.0/3.8
Alternator rating (amps) 105 105
Battery (SAE rating, cca) 525 600
Recommended unleaded fuel 87 octane 87 octane
Maximum engine speed (RPM) 6000 6500
Horsepower/kW @ engine RPM 115/85 @ 5000 150/111 @ 5600
Torque (Ib.-ft./N-m @ engine RPM) 135/100 @ 3600 155/115 @ 4400
RPO
Gear ratio
First gear
Second gear
gear
Fourth gear
Fifth gear
Reverse
Final drive ratio
Fluid capacity (quarts/liters)
Clutch size (in./mm)
- 2200 L4 engine
2.4 Liter engine
Converter size (in./mm)
Case material
MM5
3.58
2.02
1.35
0.98 °
0.69
3.31
3.94
1.5/1.7
8.85/225
8.46/215
aluminum
- MN4
2.96
1.63
1
0.68
2.14
3.63 (3.91 with 2.4L engine)
13.2/12.5 (dry)
9.6/245
aluminum
2001 Chevrolet Cavalier Restoration Kit
Ratio
Coupe/Sedan
Z24
urns stop-to-stop
Coupe/Sedan
Z24
Turning diameter curb-to-curb (ft./m)
Front Brakes
Rotor size (diam. x thick.)
Swept area
Rear Brakes
Drum size (diam. x width)
Swept area
U.S. Standard
10.2 x .79 in.
182.2 sq. in.
U.S. Standard
7.87 x 1.77 in.
- 86.2 sq. in.
14.7:1
15.7:1
2.6
2.8
35.6/10.9
Metric
260 x 20 mm
1175.6 sq. cm
Metric
200 x 45 mm
556.2 sq. cm
Page 10
2001 Chevrolet Cavalier Restoration Kit
Dimensions
Wheelbase
Length
Width
[Height
read width
front
rear
Headroom
front
rear
Legroom
front
rear
Shoulder room
front
rear.
Hip room
front
rear
Passenger volume (cu. ft./liters)
Cargo volume (cu. ft./liters)
Interior volume, EPA index (cu. ft./liters)
104.1/2644
180.9/4595
68.7/1745
53.0/1346
57.6/1463
56.4/1432
104.1/2644
37.6/955
36.6/929
41.9/1064
32.7/830
53.9/1369
54.9/1394
50.0/1270
49.5/1257
87.1/2473.3
13.2/374.8
97.0/2746.7
104.1/2644
180.9/4595
67.9/1724
54.7/1389
57.6/1463
56.7/1440
104.1/2644
38.9/988
37.2/944
41.9/1064
34.4/873
54.6/1386
53.9/1369
50.8/1290
50.6/1285
91.5/2597.9
1
13.6/386.1
05.0/2973.2
Seating 5 5
Fuel tank cap. (gal./lit. approx.) 14.3/54.2 14.3/54.2
Curb weight, estimated (Ibs./kg) 2617/1188 2676/1214
Model LS Sedan,
Z24 (with automatic transmission)
Gross trailer weight (Ibs./kg, up to) 1000/454
Max. tongue load (Ibs./kg) 100/46
! Properly equipped. Maximum trailer weight is calculated by assuming only the driver is in the tow vehicle. Optional equipment,
passengers or cargo will reduce the trailer weight rating.
Page 11
2001 Chevrolet Cavalier Restoration Kit
Cavalier History
Introduced in spring 1981 as a 1982 model.
1983 — Cyclonic induction, fuel-injected 2.0 Liter engine; convertible debuts
1984 — Cavalier is the best-selling car in the U.S.
1985 — 2.8 Liter V6 introduced; major suspension tuning
1987 — Gen Il 4- and 6-cylinder engines; Getrag 5-speed; Z24 Convertible for California only
1988 — Aerodynamic facelift for coupes and convertible; Z24 Convertible goes national
1991 — All-new interior and minor exterior changes: RS Convertible debuts
1992 — ABS VI brake system is standard; Z24 Convertible returns; Port Fuel Injection on L4
1994 — 2.2 Liter LN2 improvements; 3.1 Liter V6 option available on all Cavalier RS models
1995 — All-new interior and exterior design, new 2.3 Liter Quad 4 engine, 4T40-E transmission and
standard dual air bags |
1996 — New Daytime Running Lamps, 2.4 Liter Twin Cam engine; OBD II; extended-life coolant
1997 — Rally Sport Coupe model added, new easy-open gas cap, enhanced Evaporative Emissions
Control system and federal dynamic side-impact standards met
1998 — Z24 Convertible replaces LS Convertible; Bi-Fuel Cavalier added to the model lineup
1999 — Refined 2.4 Liter Twin Cam engine
2000 — Exterior enhancements including body-color fascias on all models; air conditioning standard on all
models; redesigned instrument panel cluster and rear-window defogger
Page 12
2001 Chevrolet Cavalier Restoration Kit
Miscellaneous Information
Technical Product information
Vehicle Classification
e Compact
Assembly Plant Locations
e Lordstown, Ohio
Frame
o Unitized
Chassis Layout |
e Front engine, front-wheel drive
‘Body Material
e Steel
Affinity Relationships
e United States Figure Skating Association and U.S. Figure Skating Team
e U.S. Soccer
e GM Concept:Cure
Recreational Towing
Recreational towing, sometimes known as flat towing or dinghy towing, is the practice of towing a vehicle
behind another vehicle where the vehicle in tow is on all four wheels. This is a common practice of motor
homerrecreational vacationers where a smaller vehicle is towed behind the motor home or coach to be
used once the vacation spot is reached. Recreational towing is not to be confused with dolly towing. Dolly
towing is the practice of placing one or both of the vehicle's axles on a dolly.
Recreational towing highlights and restrictions for the Cavalier:
e There are no engine or transmission restrictions
e Towing speed is limited to 65 mph, with no limitation on distance traveled
e The curb weight of the Cavalier must not exceed the trailer weight rating of the towing vehicle.
Approximate curb weights can be found in the Capacities and Weights section.
NOTE: It is the responsibility of the owner to properly equip the towing and towed vehicles for recreational
towing. See the Owner's Manual for restrictions and more information.
Page 13
2001 Chevrolet Cavalier Restoration Kit
Vehicie Identification
Vehicle Identification Number (VIN)
The vehicle identification number (VIN) plate is the legal identifier of the vehicle. The VIN plate is located
on the upper LH corner of the Instrument Panel and can be seen through the windshield from the outside
of the vehicle:
_ 1 U.S.A.
1 Country of Origin 3 Mexico
2 Manufacturer G General Motors
3 Make 1 Chevrolet
| 2 Pontiac
JIC Cavalier
o Co J/F Cavalier Z24 or LS
4-5 | Carline/Series J/B | Sunfire SE
J/D Sunfire GT
| 1 2 Door Coupe (37)
6 | Body Style —3 2 Door Convertible (67)
| 5 14 Door Sedan (69)
Active (Manual) Belts
7 Restraint System 2 w/Driver and Passenger
Inflatable Restraint System
3 Engine Type 4 RPO LN2, 2.2L, L4, MFI
RPO LD9, 2.4L, L4, MFI
9 Check Digit — Check Digit
10 Model! Year 1 2001
M Lansing, MI
7 Lordstown, OH
11 Plant Location 3 Lansing, Mi
S Ramos Arizpe, MEX
12-17 Plant Sequence Number | -- Plant Sequence Number
Page 14
2001 Chevrolet Cavalier Restoration Kit
VIN Derivative
All engines and transmissions are stamped or laser etched with a partial vehicle identification number
(VIN), which was derived from the complete VIN. A VIN derivative contains the following nine positions:
Chevrolet
Pontiac
Model Year 2001
GM Division Identifier
Lansing, MI
Lordstown, OH
Lansing, MI
Ramos Arizpe, MEX -
4-9 [Plant Sequence Number --
bly Plant
A VIN derivative can be used to determine if a vehicle contains the original engine or transmission, by
matching the VIN derivative positions to their. accompanying positions in the complete VIN:
4-5 12-17
Page 15
2001 Chevrolet Cavalier Restoration Kit
Label Certification
a.
~ -
s ons don | Г МЕР. BY GENERAL MOTORS CORP.
[MED. BY (GENERAL мо FORS CORP. | ® |
¡Leva | cap RT ca RR | Г] PNBU PNBEAV PNBE AR.
Г T | —| 1 I |
THIS VEHICLE CONFORMS TO ALL
THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. APPLICABLE CANADA MOTOR
FEDERAL MOTOR VEHICLE SAFETY, BUMPER AND VEHICLE SAFETY, BUMPER AND
THEFT PREVENTION STANDARDS IN EFFECT ON THEFT PREVENTION STANDARDS
THE DATE OF MANUFACTURE SHOWN TN IN EFFECT ON THE DATE OF
MANUFACTURE SHOWN ABOVE.
LL JL J |
7 TN
Name of Manufacturer
Gross Vehicle Weight-Rating
Gross Axle Weight-Rating, Front, Rear
Canadian Safety Mark (w/RPO Z49)
Certification Statement
Vehicle Class Type (Pass Car, etc. )
Vehicle Identification Number
Date of Manufacture (Mo/Yr)
INDIANA
The vehicle certification label is permanently located on the edge of the driver's door. Refer to this label in
order to obtain the following information:
e The Gross Vehicle Weight Rating (GVWR)
e The Gross Axle Weight Rating (GAWR), front and rear
The Gross Vehicle Weight (GVW) must not exceed the Gross Vehicle Weight Rating (GVWR).
The GVW is the weight of the vehicle and everything the vehicle carries. Include the following items when
figuring the GVW:
The base vehicle weight (factory weight)
The weight of any added vehicle accessories
The weight of the driver and the passenger
The weight of any cargo being carried
The front and rear Gross Axle Weights (GAW) must not exceed the Gross Axle Weight Ratings (GAWR)
front and rear .
The GAW is the weight exerted on one of the axles (front or rear).
Page 16
2001 Chevrolet Cavalier Restoration Kit
Tire Placard
Specified Occupant Seating Positions
Total Occupant Seating
Maximum Vehicle Capacity Weight
Tire Pressures, Front, Rear, and Spare
Tire Speed Rating, Front, Rear, and Spare
Tire Label Code
Engineering Model Minus First Character
Tire Sizes, Front, Rear, and Spare
Vehicle Identification Number
INFORMATION
VEHICLE
© 0 м О о К о р;
MAX. LOADING ( GVWR SAME AS VEHICLE CAPACITY The Tire Placard is permanently located on the
| | COLD TIRE edge of the driver's door: Refer to the placard in
PRESSURE order to obtain the following information:
ATG. PSI/KPa [|
The maximum vehicle capacity weight
The cold tire inflation pressures
The tire sizes--original equipment tires
The tire speed ratings--original equipment tires
Vehicle Identification Number
Wheel Base
Part Number Location
Model Designation
Order Number
Exterior Color
Paint Technology
SEVICE PARTS IDENTIFICATION DO NOT REMOVE
LISTE DES OPTIONS NF PAS ENIEVER
= 3 с
NO В о № =
The service parts identification label is placed on
the spare tire cover panel in order to help service
NE
JL] and parts personnel identify the vehicle's original
parts and the vehicle's original options.
5
Page 17
2001 Chevrolet Cavalier Restoration Kit
Engine ID and VIN Derivative Location
2.2 L VIN 4 Engine ID Location
The engine code letter is the eight digit of the VIN, which identifies the engine.
Stick-on labels attached to the engine, laser etching, or stamping in the engine block indicate the engine
unit number/build code date. |
The Machine Marking Location (1) for the 2.2 L engine.
The primary (2) and secondary (3) hand stamp locations for the Vehicle Identification Number (VIN).
2.4 VIN T Engine ID Location
The 2.4 L VIN derivative and Engine ID (1) is located on the left side of the engine block next to the
starter motor.
Page 18
2001 Chevrolet Cavalier Restoration Kit
Transmission ID and VIN Derivative Location
3T40 Transmission ID Location
МО о БОЮ
Calendar Year
Julian Date
Serial Number
Model
Model Year
Transmission ID Location
VIN Location
— 2
XX os С
O
5
—
‚99, JXC ] 0000 |
Page 19 .
2001 Chevrolet Cavalier Restoration Kit
4T40E Transmission ID Location
4 ‚9 123
— 13
A mn
OP
>
HUO— ©
Бы
CANADA
TT
1. Goodwrech Tag Location
2. Remanufacturing Site Code
3. Serial Number
Page 20
2001 Chevrolet Cavalier Restoration Kit
Automatic Transmission ID Nameplate
All automatic transmissions have a metal identification (ID) nameplate (1) attached to the case exterior.
10 ( т HYDRA-MATIC
. MADE IN U.S.A.
> |
oXXW ok
CODE NO.
Transaxle
Calendar Year
Julian Date or Day of the Year |
Shift (A=First Shift, B=Second Shift, C=Third Shift)
- Model
Serial Number in Base Code 31
Plant
Hydramatic 4T40 E
Serial Number
10. Model
11. Model Year
12. Control Number
13. Line Built (1=Line 1, 2=Line 2, 3=Line 3, 4=Line 4)
© 0 МО о В о №
2 Hydra-matic |
SERIAL NO. DIV. OF GEN. MTRS. CORP.
2SE [o 000 0000 |
Page 21
2001 Chevrolet Cavalier Restoration Kit
VIN Derivative Location 4T40/4T45-E
The Location of the Vehicle Identification Number (VIN) Derivative (1).
Getrag 5T45-E Transmission VIN Location, M86
The various possible locations for the Getrag Vehicle Identification Number (VIN) Derivative.(1)
Page 22
2001 Chevrolet Cavalier Restoration Kit
RPO Code List
The production/process codes provide the description of the Regular Production Options (RPOs) used on
the vehicle. The RPO list is printed on the Service Parts Identification Label. The following is a list of the
RPO abbreviations and the description of each:
AF5 Easy Entry Seat Adjuster: Passenger Side
AK5 |Restraint System Front Seat, Inflatable, Driver and Passenger
AR9 [Seats; Bucket, Reclining
ASS [Seats; Deluxe Bucket, Reclining, with Driver Lumbar Adjust, Seat Back Pocket, Firmer Side
Bolsters
AUO ¡Remote Keyless Entry
AU3 ¡Power Door Locks
C41 HVAC, Heater System Outside Air, With Fan
C49 iDefogger, Rear Window Electric
C60 |HVAC, Air Conditioner Front Manual Controls
C95 [Lamp Interior, Roof, Courtesy and Dual Reading
DC1 |Mirror, Outside Left Hand and Right Hand Remote Control, Electric, Defog, Tinted Glass,
Power, Foldaway, Painted
DC3 |Mirror, Outside Left Hand and Right Hand Remote Control, Electric, Defog, Tinted Glass,
Manual Foldaway, Painted
DC4 Mirror, Inside Rearview, Tilt, Dual Reading Lamps
DD2 ¡Sunvisor Vanity Mirrors
DG7 |Mirror, Outside, Remote Control, Electric, Color
DL5 ¡Decal Roadside Service Information
DT3 [Box Rear Storage Compartment
DT4 |Ashtray Cigarette Lighter |
D35 |Mirror, Outside Remote Control, Color
FEO [Suspension System Front and Rear Active
FE1 |Suspension System, Soft Ride
FE2 ¡Suspension System, Ride Handling
FP2 IRatio Transaxle Final Drive, 3.58
FX1 Ratio Transaxle Final Drive, 3.94
FX2 |Ratio Transaxle Final Drive, 3.91
FY1 . ¡Ratio Transaxle Final Drive, 3.63
IC Trim Interior Design (JC) (95)
UN Trim Interior Design (JN)
IPB (Trim Interior Design (PB)
IPD [Trim Interior Design (PD)
IPE [Trim Interior Design (PE)
IPG [Trim Interior Design (PG)
IPH Trim Interior Design (PH)
IPJ Trim Interior Design (PJ)
JA7
Park Brake Lever Handle, Leather Wrapped
Page 23
2001 Chevrolet Cavalier Restoration Kit
JM4 Brake System Power, Front Disc, Rear Drum, Cast Iron, Antilock, Front and Rear Wheel
KL6 Provisions Natural Gas
KO5 [Engine Block Heater
K29 Module Powertrain Control
K34 Cruise Control Automatic, Electronic
K62 Generator, CS 130-D, 105 Amp, Dual Internal Fan
LD9 Engine; 2.4. L4 DOHC
LN2 Engine Gas, 4 Cylinder, 2.2L, MFI
MD9 |Transmission, Automatic 3 Speed, 3T40
MN4 |Transmission, Automatic 4 Speed, 4T40E
M86 |Transmission, 5 SPD. OPEL, F23, 5T45MI
M94 Transmission, 5 SPD. OPEL, F23, 5T45MI
NK5 —|Steering Wheel Standard
NP5 |Steering Wheel Leather Wrapped
NW7 |Traction Control; Powertrain Mgmt Only
N33 — [Stg Cim, Tilt
N46 |Steering Wheel; Deluxe Urethane, w/SIR
N78 [Wheel, 14 x 6, Aluminum, Hub Cap, Wheel Nuts
N81 [Fullsize Spare Tire
PB1 Wheel Cover, 15 Inch
PC1 Wheel, 14 x 6, Aluminum
PF7 |Wheel, 15 x 6, Aluminum Cast, Styled
PGO ¡Wheel 16 x 6, Aluminum, Styled
PG1 ¡Wheel 14 x 6, Steel
OFB |P195/70 R14 All Season, Black Wall Tires
QLG |P205/55 R16 Performance: Black Wall Tire
QPD |P195/65 R15 Touring; Black Wall Tires
T43 Spoiler Rear
179 Fog Lamp, Rear
184 [Headlamps Right Hand Rule of the Road, E Mark
UD4 ¡Alarm Vehicle Speed, 120 K/H
UH7 [Cluster Instrument, Cool Temp
UH8 [Cluster Instrument, Cool Temp, Trip Odom, Tach
UJS Cluster Instrument, Cool Temp, Trip Odom, Tach, Fuel, Speedo, Analog, Metric Only
UK3 |Radio Control; Redundant on Steering Wheel
ULO Radio, AM/FM Stereo, Seek/Scan, Auto Reverse Music Search Cassette, Auto Tone, Clock
UM6 |Radio; AM/FM Stereo Seek/Scan, Auto Reverse, Cassette, Clock
UM7 |Radio, AM/FM Stereo, Seek/Scan, Clock
UNO |Radio, AM/FM, Stereo, Seek/Scan, Compact Disc, Auto Tone, Clock
UNG Radio, AM/FM, Stereo, Seek/Scan, Auto Reverse Music Search Cassette, Clock
UP3 |Radio, AM/FM, Stereo, Seek/Scan, Compact Disc, Equalizer, Clock
UQ9 ¡Speaker Delete
Page 24
2001 Chevrolet Cavalier Restoration Kit
US6 ¡Antenna Fixed, Painted, Radio |
UT6 |Radio; AM/FM Stereo, Seek/Scan Auto Reverse Music Search, Cassette, Equalizer, Clock
UW6 |6 Speaker System, Dual F/D Tweet and Woof, Dual Extended Range Shelf
UX7 — |Speaker System 4, Dual Front Door Mounted, Dual Extended Range Package Shelf
U19 Metric Scale Instrument Cluster
U77 Antenna Rear Window, Radio
U79 ¡Speakers (4), 2 Rear Shelf, 1 Coaxial per Door
VD9 ¡|Fascia Front and Rear, Body Color
VG9 (Protector Wax, Exterior Body
VH4 |Front Mud Guards — |
VH9 |Envelope Owner Information Manual
VK3 [Front License Plate Mounting Provisions
VP6 [Noise Control
VR6 [Hook Tie Down
VY7 — |Leather Shift Knob
Vos [Radiator Heavy Duty
01L Secondary Color Exterior, Special (91)
101 Interior Trim Arctic White (93)
10N |Trim Combination Vinyl, Arctic White (N) (93)
12B |Trim Combination Cloth, Graphite (B) (95)
12C |Trim Combination Cloth Graphite (C) (94)
12D |Trim Combination Cloth, Graphite (D) (95)
12E [Trim Combination Cloth, Graphite (E) (92)
126 |Trim Combination Cloth, Graphite (G) (96)
12H |Trim Combination Cloth, Graphite (H) (96)
121 Interior Trim Graphite (95) |
12J Trim Combination Cloth, Graphite (J) (98)
16T |Top Color Bright White (94)
16U |Primary Color Exterior, Brite White (91)
22U |Primary Color Exterior, Dahlia Blue Met (97)
24U 1|Primary Color Exterior, Opal Blue (97)
36U |Primary Color Exterior, Fern Green Mint (99)
37U' |Primary Color Exterior, Manta Green Met (96)
41T ¡Top Color Black (91)
41U |Primary Color Exterior, Black (94)
49U [Primary Color Exterior, Light Sandrift Met (96)
52B |Trim Combination Cloth, Light Neutral (B) (92)
52C |Trim Combination Cloth, Light Neutral (C) (95)
52D [Trim Combination Cloth, Light Neutral (D) (96)
52E |Trim Combination Cloth, Light Neutral (E) (96)
5926 [Trim Combination Cloth, Light Neutral (G) (96)
52H [Trim Combination Cloth, Medium Neutral II (H) (96)
Page 25
2001 Chevrolet Cavalier Restoration Kit
521 |Interior Trim, Light Neutral (1) (92)
52N — |Trim Combination Vinyl, Light Neutral (N) (96)
521 Top Color Neutral
60U [Primary Color Exterior, Gold Firemist (98)
8X1 Label Fastener Seat Belts
81U Primary Color Exterior, Bright Red (91)
92B [Trim Combination Cloth, Pewter (B) (97)
92E [Trim Combination Cloth, Medium Dark Pewter (97) (E)
92G [Trim Combination Cloth, Medium Dark Pewter (97) (С)
92H - [Trim Combination Cloth, Medium Dark Pewter (97) (H)
921 Interior Trim Pewter (97)
96U |Primary Color Exterior, Cayenne Red Metallic (96)
Page 26
2001 Chevrolet Cavalier Restoration Kit
Technical Information
Maintenance and Lubrication
Capacities - Approximate Fluid
Engine Cooling, 2.2
Engine Cooling, 2.4L
With Filter
Fuel Tank
13140 Transaxle Bottom Pan Removal
3140 Transaxle Complete Overhaul
4T40E/4T45E Transaxle Bottom Pan Removal
41T40E/4T45E Transaxle Complete Overhaul
Manual Transaxle Complete Drain and Refill
~ Tire Inflation Pressure Specifications
Tire Inflation; Compact Spare
420 kPa 60psi
Tire Inflation; Front Tires
210 kPa 30 psi
Tire Inflation; Rear Tires
210 kPa 30 psi
Maintenance Items
Air Cleaner Filter, 2.2L
Air Cleaner Filter, 2.4L
Engine Oil Filter, 2.2L
Engine Oil Filter, 2.4L
Spark Plug and Gap, 2.2L
Spark Plug and Gap, 2.4L
Driver's Side
Passengers's Side
AC Type A-1172C
AC Type A-1172C
AC Type PF47
AC Type PF44
AC Type 41-928, 1.27 mm (0.050 in) Gap
AC Type 41-963, 1.27 mm (0.050 in) Gap
Shepherd's Hook Type 56 cm (22 in)
Shepherd's Hook Type 43 cm (17 in)
Page 27
2001 Chevrolet Cavalier Restoration Kit
Fluid and Lubricant Recommendations
Automatic Transaxle
DEXRONOE-III Automatic Transaxle Fluid
Chassis Lubrication
Chassis Lubrication GM P/N 12377985 or equivalent or lubricant meeting
requirements of NLGI # 2, Category LB or GC-LB
Clutch Linkage Pivot
Points
Engine oil
Engine Coolant
50/50 mixture of clean, drinkable water and use only GM Goodwrench® DEX-
COOL® or Havoline® DEX-COOL® coolant
Engine Oil
Engine oil with the American Petroleum Institute Certified for Gasoline Engines
"Starburst" symbol of the proper viscosity. To determine the preferred viscosity
for your vehicle's engine, refer to Engine Oil Viscosity in your owner's manual.
Hinges, Hood and Door
Multi-Purpose Lubricant, Superlube ® GM P/N 12346241 or equivalent
Hood Latch Assembly,
Secondary Latch, Pivots,
Spring Anchor and
Release Pawl
Lubriplate ® Lubricant Aerosol GM P/N 12346293 or equivalent or lubricant
meeting requirements of NLGI # 2, Category LB or GC-LB
Hydraulic Brake System
Delco Supreme 11® Brake Fluid GM P/N 12377967 or equivalent DOT-3
brake fluid
Hydraulic Clutch System
Hydraulic Clutch Fluid GM P/N 12345347 or equivalent DOT-3 Brake Fluid
Key Lock Cylinders
Multi-Purpose Lubricant, Superlube ® GM P/N 12346241
|
Manual Transaxle
Dexron® Ill-Automatic Transaxle Fluid
Manual Transaxle Shift
Linkage
Chassis Lubricant GM P/N 12377985 or equivalent or lubricant meeting
requirements of NLGI # 2, Category LB or GC-LB
Power Steering System
GM Power Steering Fluid GM P/N 1052884 - 1 pint or 1050017 - 1 quart, or
equivalent
Weatherstrip Conditioning
Dielectric Silicone Grease GM P/N 12345579 or equivalent
Windshield Washer
GM Optikleen® Washer Solvent GM P/N 1051515 or equivalent
Solvent
Page 28
2001 Chevrolet Cavalier Restoration Kit
Tire and Wheel Runout Specifications
Tire and Wheel Assembly - Lateral and Rad jal
e Off-Vehicle
1.27 mm
0.050 in
e On-Vehicle
1.52 mM
0.060 in
e Lateral
0.762 mm
0.030 in
0.762 mm
0.030 in
e Radial
e Lateral
1.143 mm
0.045 in
e Radial |
1.015 mm
0.040 in
0.132 mm
0.0052 in
0.25 mm
0.010 in
— Page 29
2001 Chevrolet Cavalier Restoration Kit
Descriptions and Operations
Power Steering System Description and Operation w/o Electro-
Hydraulic Steering
The hydraulic power steering pump is a constant displacement vane-type pump that provides hydraulic
pressure and flow for the power steering gear. The hydraulic power steering pumps are either belt-driven
or direct-drive, cam-driven.
The power steering fluid reservoir holds the power steering fluid and may be integral with the power
steering pump or remotely located. The following locations are typical locations for the remote reservoir:
e Mounted to the front of the dash panel
e Mounted to the inner fender
‚ ® Mounted to a bracket on the engine
The 2 basic types of power steering gears are listed below:
e À recirculating ball system
e À rack and pinion system
In the recirculating ball system, a worm gear converts steering wheel movement to movement of a sector
shaft. À pitman arm attached to the bottom of the sector shaft actually moves one tie rod and an
intermediate rod move the other tie rod.
In the rack and pinion system, the rack and the pinion are the 2 components that convert steering wheel
rotation to lateral movement. The steering shaft is attached to the pinion in the steering gear. The pinion
rotates with the steering wheel. Gear teeth on the pinion mesh with the gear teeth on the rack. The
rotating pinion moves the rack from side to side. The lateral action of the rack pushes and pulls the tie
rods in order to change the direction of the vehicle's front wheels.
The power steering pressure hose connects the power steering pump union fitting to the power steering
gear and allows pressurized power steering fluid to flow from the pump to the gear.
The power steering return hose returns fluid from the power steering gear back to the power steering fluid
reservoir. The power steering return line may contain an integral fin-type or line-type power steering fluid
cooler.
In a typical power steering system, a pump generates hydraulic pressure, causing fluid to flow, via the
pressure hose, to the steering gear valve assembly. The steering gear valve assembly regulates the
incoming fluid to the right and left chambers in order to assist in right and left turns.
Turning the steering wheel activates the valve assembly, which applies greater fluid pressure and flow to
1 side of the steering gear piston, and lower pressure and flow to the other side of the piston. The
pressure assists the movement of the gear piston. Tie rods transfer this force to the front wheels, which
turn the vehicle right or left.
Steering Wheel and Column - Standard Description and Operation
The steering wheel and column has 4 primary functions:
Vehicle steering
Vehicle security
Driver convenience
Driver safety
Page 30
2001 Chevrolet Cavalier Restoration Kit
Vehicle Steering
The steering wheel is the first link between the driver and the vehicle. The steering wheel is fastened to a
steering shaft within the column. At the lower end of the column, the intermediate shaft connects the
column to the steering gear.
Vehicle Security
Theft deterrent components are mounted and designed into the steering column. The following
components allow the column to be locked in order to minimize theft:
e The ignition switch
e The steering column lock
e The ignition cylinder
Driver Convenience
The steering wheel and column may also have driver controls attached for convenience and comfort. The
following controls may be mounted on or near the steering wheel or column.
The turn signal switch
The hazard switch
The headlamp dimmer switch
The wiper/washer switch
The horn pad/cruise control switch |
. The redundant radio/entertainment system controls
The tilt or tilt/telescoping functions
The HVAC controls
Driver Safety
The energy-absorbing steering column compresses in the event of a front-end collision, which reduces
the chance of injury to the driver. The mounting capsules break away from the mounting bracket in the
event of an accident. | |
Suspension Description and Operation
Front Suspension
The front suspension has 2 primary purposes:
e Isolate the driver from irregularities in the road surface.
* Define the ride and handling characteristics of the vehicle.
The front suspension absorbs the impact of the tires travelling over irregular road surfaces and dissipates
this energy throughout the suspension system. This process isolates the vehicle occupants from the road
surface. The rate at which the suspension dissipates the energy and the amount of energy that is
absorbed is how the suspension defines the vehicles ride characteristics. Ride characteristics are
designed into the suspension system and are not adjustable. The ride characteristics are mentioned in
this description in order to aid in the understanding of the functions of the suspension system. The
suspension system must allow for the vertical movement of the tire and wheel assembly as the vehicle
travels over irregular road surfaces while maintaining the tire's horizontal relationship to the road.
This requires that the steering knuckle be suspended between a lower control arm and a strut assembly.
The lower control arm attaches from the steering knuckle at the outermost point of the control arm. The
attachment is through a ball and socket type joint. The innermost end of the control arm attached at 2
points to the vehicle frame through semi-rigid bushings. The upper portion of the steering knuckle is
Page 31
2001 Chevrolet Cavalier Restoration Kit
attached to a strut assembly. The strut assembly then connects to the vehicle body by way of an upper
bearing. The steering knuckle is allowed to travel up and down independent of the vehicle body structure
and frame.
This up and down motion of the steering knuckle as the vehicle travels over bumps is absorbed
predominantly by the coil spring. This spring is retained under tension over the strut assembly. A strut is
used in conjunction with this system in order to dampen out the oscillations of the coil spring. A strut is a
basic hydraulic cylinder. The strut is filled with oil and has a moveable shaft that connects to a piston
inside the strut. Valves inside the shock absorber offer resistance to oil flow and consequently inhibit
rapid movement of the piston and shaft. Each end of the shock absorber is connected in such a fashion to
utilize this recoil action of a spring alone. Each end of the strut is designed as the connection point of the
suspension system to the vehicle and acts as the coil spring seat. This allows the strut to utilize the
dampening action to reduce the recoil of a spring alone. The lower control arm is allowed to pivot at the
vehicle frame in a vertical fashion. The ball joint allows the steering knuckle to maintain the perpendicular
relationship to the road surface. |
Front suspensions systems utilize a stabilizer shaft. The stabilizer bar connects between the left and right
lower control arm assemblies through the stabilizer link and stabilizer shaft insulators. This bar controls
the amount of independent movement of the suspension when the vehicle turns. Limiting the independent
movement defines the vehicles handling characteristics on turns. -
Rear Suspension
This vehicle has a semi-independent rear suspension which consists of the following components:
e An axle with trailing arms
e A twisting cross beam
e 2 coil shocks
The axle assembly attaches to the underbody through a rubber bushing located at the front of each
control arm. The brackets are integral with the underbody side rails. The axle structure itself maintains the
geometrical relationship of the wheels relative to the inside of the body. The stabilizer shaft is attached to
the inside of the axle beam. | |
The coil springs support the weight of the vehicle in the rear. A rubber insulator isolates the coil spring
upper spring seat. |
The lower ends of the coil-over shocks are attached to the axle assembly, by a bracket which has a stud
that is fastened to the axle using a nut. The upper ends are attached to the body of the car. The top of the
coil-over shock has an insulator which is bolted to the body near the wheel-house area. The coil-over
shock absorbers are non-adjustable and non-refillable. Service of the coil-over shocks require
replacement of the inner shock assembly. This is when they have lost their resistance, are damaged or
are leaking.
A single hub and bearing assembly is bolted to both ends of the rear axle assembly or the rear knuckle
assembly. This hub and bearing assembly is a sealed unit which eliminated the need for wheel bearing
adjustments and does not require periodic maintenance.
Wheels and Tires
General Description
The factory installed tires are designed to operate satisfactorily with loads up to and including the full
rated load capacity when these tires are inflated to the recommended pressures.
The following factors have an important influence on tire life:
e Correct tire pressures
Page 32
2001 Chevrolet Cavalier Restoration Kit
e Correct wheel alignment
e Proper driving techniques
e Tire rotation
The following factors increase tire wear:
e Heavy cornering
e Excessively rapid acceleration
e Heavy braking
Tread Wear Indicators Description
The original equipment tires have tread wear indicators that show when
7 INS
you should replace the tires.
CA |
Ся SE The location of these indicators are at 72 degree intervals around the outer"
С №" diameter of the tire. The indicators appear.as a 6 mm (0.25 in) wide band
с NT when the tire tread depth becomes 1.6 mm (2/32 in).
|
AS
cf ds
Metric Wheel Nuts and Bolts Description
Metric wheel/nuts and bolts are identified in the following way:
* The wheel/nut has the word Metric stamped on the face.
e The letter M is stamped on the end of the wheel bolt.
The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5.
e M= Metric
12 = Diameter in millimeters
1.5 = Millimeters gap per thread
Tire Inflation Description
When you inflate the tires to the recommended inflation pressures, the factory-installed wheels and tires
are designed in order to handle loads to the tire's rated load capacity. Incorrect tire pressures, or under-
inflated tires, can cause the following conditions:
Vehicle handling concerns
Poor fuel economy
Shortened tire life
Tire overloading
Inspect the tire pressure when the following conditions apply:
e The vehicle has been sitting at least 3 hours. |
e The vehicle has not been driven for more than 1.6 km (1 mi).
e The tires are cool.
Inspect the tires monthly or before any extended trip. Adjust the tire pressure to the specifications on the
tire label. Install the valve caps or the extensions on the valves. The caps or the extensions keep out dust
and water.
Page 33 |
2001 Chevrolet Cavalier Restoration Kit
The kilopascal (kPa) is the metric term for pressure. The tire pressure may be printed in both kilopascal
(kPa) and psi. One psi equals 6.9 kPa.
Inflation Pressure Conversion (Kilopascals to PSI)
140 | 20 215
145 21 220
155 22 230
160 23 235
165 24 240
170 25 250
180 26 275
185 27 310
190 28 345
200 29 380
205 30 415
® A hard ride
e Tire bruising
e Rapid tread wear at the center of the tire
Tires with a lower than recommended pressure can cause the following conditions:
A tire squeal on turns
Hard steering
Rapid wear and uneven wear on the edge of the tread
Tire rim bruises and tire rim rupture
Tire cord breakage
High tire temperatures
Reduced vehicle handling
High fuel consumption
Soft riding
Unequal pressure on the same axle can cause the following conditions:
e Uneven braking
e Steering lead
e Reduced vehicle handling
Refer to the Tire Placard for specific tire and wheel applications and tire pressures.
Page 34
2001 Chevrolet Cavalier Restoration Kit
P-Metric Sized Tires Description
Р 245 / БОВ 16 95$
ТТ РТ
TIRE TYPE | [LOAD INDEX
P—PASSENGER
I= TEMPORARY [SPEED SYMBOL
SECTION
WIDTH RIM ___|
(MILLIMETERS) DIAMETER
(2353 RE | (INCHES)
245 ——- 16
275 17
ASTECT [CONSTRUCTION
(SECTION HEIGHT) RADA
(SECTION: WIDTH) B—BIAS—BELTED
22 D— DIAGONAL (BIAS)
40
SECTION
WIDTH
SECTION
HEIGHT
_V
Most P-metric tire sizes do not have exact corresponding alphanumeric tire sizes. Replacement tires
should be of the same tire performance criteria (TPC) specification number including the same size, the
same load range, and the same construction as those originally installed on the vehicle. Consult a tire
dealer if you must replace the P-metric tire with other sizes. Tire companies can best recommend the
closest match of alphanumeric to P-metric sizes within their own tire lines.
Braking System Description and Operation
Hydraulic Brake System Description and Operation
System Component Description
The hydraulic brake system consists of the following:
Hydraulic Brake Master Cylinder Fluid Reservoir
Contains supply of brake fluid for the hydraulic brake system.
Hydraulic Brake Master Cylinder
Converts mechanical input force into hydraulic output pressure.
Hydraulic output pressure is distributed from the master cylinder through two hydraulic circuits,
supplying diagonally-opposed wheel apply circuits.
Page 35
2001 Chevrolet Cavalier Restoration Kit
Hydraulic Brake Pressure Balance Control System
Regulates brake fluid pressure delivered to hydraulic brake wheel circuits, in order to control the
distribution of braking force.
Pressure balance control is achieved through dynamic rear proportioning (DRP), which is a function
of the ABS modulator. |
Hydraulic Brake Pipes and Flexible Brake Hoses
Carries brake fluid to and from hydraulic brake system components.
Hydraulic Brake Wheel Apply Components
Converts hydraulic input pressure into mechanical output force.
System Operation
Mechanical force is converted into hydraulic pressure by the master cylinder, regulated to meet braking
system demands by the pressure balance control system, and delivered to the hydraulic brake wheel
circuits by the pipes and flexible hoses. The wheel apply components then convert the hydraulic pressure
back into mechanical force which presses linings against rotating brake system components.
Brake Assist System Description and Operation
System Component Description
The brake assist system consists of the following:
Brake Pedal
Receives, multiplies and transfers brake system input force from driver.
Brake Pedal Pushrod
Transfers multiplied input force received from brake pedal to brake booster.
Vacuum Brake Booster
Uses source vacuum to decrease effort required by driver when applying brake system input force.
When brake system input force is applied, air at atmospheric pressure is admitted to the rear of both
vacuum diaphragms, providing a decrease in brake pedal effort required. When input force is
removed, vacuum replaces atmospheric pressure within the booster.
Vacuum Source
Supplies force used by vacuum brake booster to decrease brake pedal effort.
Vacuum Source Delivery System
Enables delivery and retention of source vacuum for vacuum brake booster.
System Operation
Brake system input force is multiplied by the brake pedal and transferred by the pedal pushrod to the
hydraulic brake master cylinder. Effort required to apply the brake system is reduced by the vacuum
brake booster. |
Page 36
2001 Chevrolet Cavalier Restoration Kit
Disc Brake System Description and Operation
System Component Description
The disc brake system consists of the following components:
Disc Brake Pads
Applies mechanical output force from the hydraulic brake calipers to friction surfaces of brake rotors.
Disc Brake Rotors |
Uses mechanical output force applied to friction surfaces from the disc brake pads to slow speed of
- tire and wheel assembly rotation.
Disc Brake Pad Hardware
Secures disc brake pads firmly in proper relationship to the hydraulic brake calipers. Enables a sliding
motion of brake pads when mechanical output force is applied.
Disc Brake Caliper Hardware
Provides mounting for hydraulic brake caliper and secures the caliper firmly in proper relationship to
caliper bracket. Enables a sliding motion of the brake caliper to the brake pads when mechanical
output force is applied.
System Operation
Mechanical output force is applied from the hydraulic brake caliper pistons to the inner brake pads. As the
pistons press the inner brake pads outward, the caliper housings draw the outer brake pads inward. This
allows the output force to be equally distributed. The brake pads apply the output force to the friction
surfaces on both sides of the brake rotors, which slows the rotation of the tire and wheel assemblies. The
correct function of both the brake pad and brake caliper hardware is essential for even distribution of
braking force.
Drum Brake System Description and Operation
System Component Description
The drum brake system consists of the following:
Drum Brake Shoes
Applies mechanical output force (from hydraulic brake wheel cylinders) to friction surface of brake
drums. |
Brake Drums
Uses mechanical output force applied to friction surface from drum brake shoes to slow speed of tire
and wheel assembly rotation. |
Drum Brake Hardware
Secures drum brake shoes firmly in proper relationship to hydraulic brake wheel cylinders. Enables
sliding motion of brake shoes needed to expand toward friction surface of drums when mechanical
output force is applied; provides return of brake shoes when mechanical output force is relieved.
Drum Brake Adjusting Hardware
Provides automatic adjustment of brake shoes to brake drum friction surface whenever brake apply
occurs during rearward motion of the vehicle.
Page 37
2001 Chevrolet Cavalier Restoration Kit
System Operation
Mechanical output force is applied from the hydraulic brake wheel cylinder pistons to the top of the drum
brake shoes. The output force is then distributed between the primary and secondary brake shoes as the
shoes expand toward the friction surface of the brake drums. The brake shoes apply the output force to
the friction surface of the brake drums, which slows the rotation of the tire and wheel assemblies. The
proper function of both the drum brake hardware and adjusting hardware is essential to the proper
distribution of braking force.
Park Brake System Description and Operation
System Component Description
The park brake system consists of the following:
Park Brake Lever Assembly
Receives, multiplies, and transfers park brake system apply Input force from operator to park brake
. cable system.
Releases applied park brake system when lever is returned to at-rest, lowered, position.
Park Brake Cables
Transfers input force received from park brake lever, through park brake cable equalizer, to park
brake apply levers.
Park Brake Cable Equalizer |
Evenly distributes input force to both the left and right park brake units.
Park Brake Apply Lever
Multiplies and transfers input force to park brake actuator/adjuster.
| Park Brake Actuator/Adjuster
Uses multiplied input force from apply lever to expand drum brake shoes toward the friction surface of
the brake drum.
Threaded park brake actuators/adjusters are also used to control clearance between the drum brake
shoes and the friction surface of the brake drum.
Drum Brake Shoes
Applies mechanical output force from park brake actuator/adjuster to friction surface of the brake
drum. |
System Operation
Park brake apply input force is received by the park brake lever assembly being applied. The input force
is multiplied by the lever assembly, transferred, and evenly distributed, through the park brake cables and
the park brake cable equalizer, to the left and right park brake apply levers. The park brake apply levers
multiply and transfer the apply input force to the park brake actuators/adjusters which expand the drum
brake shoes toward the friction surface of the brake drum in order to prevent the rotation of the rear tire
and wheel assemblies. The park brake lever assembly releases an applied park brake system when it is
returned to the at-rest, lowered, position.
Page 38
2001 Chevrolet Cavalier Restoration Kit
ABS Description and Operation
Antilock Brake System
When wheel slip is detected during a brake application, the ABS enters antilock mode. During antilock
braking, hydraulic pressure in the individual wheel circuits is controlled to prevent any wheel from
slipping. A separate hydraulic line and specific solenoid valves are provided for each wheel. The ABS can
decrease, hold, or increase hydraulic pressure to each wheel brake. The ABS cannot, however, increase
hydraulic pressure above the amount which is transmitted by the master cylinder during braking.
During antilock braking, a series of rapid pulsations is felt in the brake pedal. These pulsations are
caused by the rapid changes in position of the individual solenoid valves as the EBCM responds to wheel
speed sensor inputs and attempts to prevent wheel slip. These pedal pulsations are present only during
antilock braking and stop when normal braking is resumed or when the vehicle comes to a stop. A ticking
or popping noise may also be heard as the solenoid valves cycle rapidly. During antilock braking on dry
pavement, intermittent chirping noises may be heard as the tires approach slipping. These noises and
pedal pulsations are considered normal during antilock operation.
Vehicles equipped with ABS may be stopped by applying normal force to the brake pedal. Brake pedal
operation during normal braking is no different than that of previous non-ABS systems. Maintaining a -
constant force on the brake pedal provides the shortest stopping distance while maintaining vehicle
stability.
Page 39
2001 Chevrolet Cavalier Restoration Kit —
Engine Description and Operation
Engine Mechanical — 2.2L
neral Data
Type L-4
lar Production Option (RPO) Code LN2 VIN Code 4/L43 VIN Code 5
ent | 2.2 | 134 СЮ
89 mm 3.5 in
| 88 mm | 3.46 in
pression Ratio 9:1
Order 1-3-4-2
Pressure @ 65°C (150°F)
Fastener Tightening Specifications
56 psi @ 3000 RPM _
Accessory Drive Belt Idier Pulley 50 Nm 37 lb ft
Air Conditioning Compressor Mounting Bolts 54 N-m 40 lb ft
Camshaft Sprocket Bolt 130 N-m 96 Ib ft
Crankcase Front Cover Bolts 11 N-m. 97 Ib in
Crankshaft Pulley Hub to Crankshaft Bolts 105 N-m 77 lo ft
Crankshaft Pulley to Hub Bolt 50 N-m 37 loft
Cylinder Head Bolts -- Long В | | |
e First Pass 63N-m | 461bft
e Final Pass | | 90 degrees
Cylinder Head Bolts -- Short
e First Pass | | 58 №т | 43168
e Final Pass 90 degrees
Engine Bracket to Mount Bolt | 60N'm | 44lbft
e Final Pass 90 degrees
Engine Mount to Body Nut | 75 IbN-m 55 lb ft
Engine Mount Strut Bolts 100 IbN-m 74 |b ft
e Final Pass 90 degrees
Engine Mount Strut Bracket Bolts 66 N:m 49 Ib ft
|Flywheel Bolts 75 N-m 55 Ib ft
Fuel Inlet Pipe Bolt 24 №т 17 lb ft
Intake Manifold Bolts 24 N-m 17 lb ft
Intake Manifold Nuts 24 N-m 17 lb ft
Intake Manifold Studs 12 N-m 105 lb in
Lifter Guide 11 N-m 97 Ib in
Page 40
2001 Chevrolet Cavalier Restoration Kit
Negative Battery Cable Bolt 16 N-m 12 lb ft
Oil Fill Tube 50 N'-m 37 Ib ft
Oil Filter 17 N-m 13 Ib ft
Oil Filter Adapter 35 N-m 26 Ib ft
Oil Pan 10 N-m 89 Ib in
Oil Pan Drain Bolt 26 N-m 19 Ib ft
Oil Pump Cover Bolts 10 N-m 89 lb in
Oil Pump Drive Assembly 25 N-m 18 lb ft
Oil Pump Mounting Bolt 44 N-m 32 Ib ft
Resonator Nut 25 N-m 19 Ib ft
¡Rocker Arm Bolts 25 N-m 19 lb ft
Rocker Arm Cover Bolts 10 N-m 89 lb in
Serpentine Drive Belt Tensioner Bolt 50 N-m 37 lb ft
Spark Plugs 17 N-m 13 Ib ft
Timing Chain Tensioner Bolts 24 Nm 18 lb ft
Transmission Bolts 75 N-m 55 Ib ft
Drive Belt System Description
The drive belt system consists of the following components:
The drive belt
The drive belt tensioner
The drive belt idler pulley
The crankshaft balancer pulley
e e e e e e
The accessory drive components
The power steering pump, if belt driven |
The generator
The A/C compressor, if equipped
The engine cooling fan, if belt driven
The water pump, if belt driven
The vacuum pump, if equipped
The air compressor, if equipped
The accessory drive component mounting brackets
The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend backwards
and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to
drive certain accessory drive components. The drive belts are made of different types of rubbers
(chloroprene or EPDM) and have different layers or plys containing either fiber cloth or cords for
reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive com ponents. When the
back side of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys.
The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt
from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the
accessory drive components and the crankshaft.
The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some
systems use an idler pulley in place of an accessory ¢ drive component when the vehicle is not equipped
with the accessory.
Page 41
2001 Chevrolet Cavalier Restoration Kit
Engine Mechanical — 2.4L
neral Data
ne Type Inline 4 Cylinder
146 CID
ent | | 24L
lar Production Option (RPO) Code LD9 VIN Code T
3.54 in
3.70 in
90 mm
94 mm
9.5 to 1
1-3-4-2
0.076 mm.
0.076-0.25 mm
troke
pression Ratio
Order
Not Resurface if the Overall Measurement is Less Than
the Head if the Overall Measurement is More Than
System
Pressure @ 3,000 RPM
Pressure @ 900 RPM
0.003 in
0.003-0.010 in
207 kPa
69 kPa
30 psi min
10 psi min
Fastener Tightening Specifications
Application Specification
Metric | English
Camshaft Housing Cover to Camshaft Housing Bolt (First pass) 15 N-m 11 Ib ft
e Final Pass 30 degrees
~ [Camshaft Housing to Cylinder Head Bolt (First pass) 15 N-m 11 Ib ft
e Final Pass | 90 degrees
Camshaft Sprocket Bolt 70 N-m 52 Ib ft
Crankshaft Balancer Bolt (First pass) 175 N-m | 129 |b ft
e Final Pass 90 degrees
Drive Belt Tensioner Bolt 50 №т | 37 lb ft
Engine Brace to Transmission Bolt 50 N-m 37 Ib ft
Engine Front Cover Bolt 13 №т | 11516 п
Engine Mount to Body Nut 75 N-m 55 Ib ft
Engine Mount Bracket Adapter Bolt (First pass) 60 N-m 44 |b ft
e Final Pass | 60 degrees
Engine Mount Bracket to Engine Block Bolt (Side) 58 N-m 43 Ib ft
Engine Mount Bracket to Engine Block Bolt (Front) 102 N-m | 75lbft
Engine Mount Bracket to Transaxle Bolt 75 N-m 55 |b ft
Engine Mount to Engine Mount Bracket (First pass) 60 N-m 44 |b ft
e Final Pass 90 degrees
Engine Mount Strut Bolt (First pass) 100 N-m | 74 1b ft
e Final Pass 90 degrees
Engine Mount Strut Bracket Bolt 66 N-m 49 Ib ft
Flywheel Bolt (First pass) 30 N-m 22 lb ft
Page 42
2001 Chevrolet Cavalier Restoration Kit
e Final Pass 45 degrees
Fuel Rail to Camshaft Housing Bolt 26 N'm 19 Ib ft
Ignition Coil/Module Cover to Camshaft Housing Bolt (First pass) 15 N'm 11 Ib ft
e Final Pass 30 degrees
Intake Camshaft Sprocket Bolt 70 N-m 52 lb ft
Intake Manifold Bolt/Nut | 24 N-.m 18 Ib ft
Oil/Air Separator to Engine Block Bolt 24N-m | 17 Ib ft
Oil Filter Adapter 29N-m | 211Ibft
Oil Level Indicator Tube Nut 8 N-m 72 Ibin
Oil Pan Bolt 26 N'm 19 Ib ft
e M8x1.25x80 24 N-m 18 lb ft
e M8x1.25x22 24 N-m 18 lb ft
e M6x1.00x25 12 N-m | 106lb in
Oil Pan Drain Bolt 26 N-m 19 Ib ft
Oil Pan to Seal Housing Bolt 12N-m | 106 Ib in
Oil Pump Cover to Balance Shaft Housing Bolt 54 N-m | 40lbft
[Timing Chain Housing Bolt
e M8 x 1.25 x 25 Bolt 26 N-m 19 lb ft
e M8 x 1.55 x 55 Bolt 50 N-m | 37lbft
e M10 x 1.25 x 35 Bolt 29 N-m 21 lb ft
e M8 x 1.25 x 80 Bolt 24 N-m 18 lb ft
e M8 x 1.24 x 22 Bolt 24 N-m 18 lb ft
e M6 x 1.00 x 25 Bolt 12N-m | 106 Ib in
Timing Chain Housing Nut 26N-m | 191btt
Timing Chain Tensioner Bolt 10 №т | 8916 п
Engine Cooling
Engine Cooling System Approximate Capacities
2.4 L Engine (RPO LD9)
94L
9.9 at
Fastener Tightening Specifications
ir Bleed Pipe Bolt 14 N-m 10 lb ft
Air Bleed Pipe Nut 42 N-m 31 Ib ft
Cooling Fan Bolt 6 N-m 53 lb in
Coolant Inlet Housing Bolt-2.4L _ 14 N-m 10 Ib ft
Page 43
2001 Chevrolet Cavalier Restoration Kit
Coolant Inlet Housing Stud--2.4L 26 N-m 19 Ib ft
Coolant Pipe Inlet Bolt 14 N-m 10 Ib ft
Coolant Pipe Inlet Cover Bolt 14N-m | 10Ib ft
Coolant Pipe Inlet to Oil Pan 26 N-.m 19 Ib ft
Coolant Pump Bolt-2.2L 25 N-m 18 Ib ft
Coolant Pump Cover Bolt--2.4L 14 N-m 10 lb ft
Coolant Pump Cover to Engine Block Bolt-2.4L 26 N-m 19 Ib ft
Coolant Pump Pulley Bolt-2.2L 30 N-m 22 |b ft
Coolant Pump to Timing Chain Housing Nut-2.4L 26 N'm 19 Ib ft
Coolant Outlet Bolt-2.2L 14 N-m 10 Ib ft
Exhaust Manifold Heat Shield Bolt -2.4L 14 N'm 10 Ib ft
Radiator Outlet Pipe Cover Bolt 14 N-m 10 lb ft
Radiator Outlet Pipe to Oil Pan Bolt 26 N-m 19 lb ft
Surge Tank Bolt | 10 N-m 89 Ib in
[Transmission Oil Cooler Line Fitting | 36 №т | 271bft
Upper Radiator Mount Bolt 10 N-.m 89 Ib in
Cooling System Description and Operation
Coolant Heater
The optional engine coolant heater (RPO K05) operates using 110-volt AC external power and is
designed to warm the coolant in the engine block area for improved starting in very cold weather -29°C (-
20°F). The coolant heater helps reduce fuel consumption when a cold engine is warming up. The unit is
equipped with a detachable AC power cord. A weather shield on the cord is provided to protect the plug
when not in use.
Cooling System
The cooling system's function is to maintain an efficient engine operating temperature during all engine
speeds and operating conditions. The cooling system is designed to remove approximately one-third of
the heat produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not
flow to the radiator until the thermostat opens. This allows the engine to warm quickly.
Cooling Cycle
Coolant flows from the radiator outlet and into the water pump inlet. Some coolant flows from the water
pump, to the heater core, then back to the water pump. This provides the passenger compartment with
heat and defrost capability as the coolant warms up.
Coolant also flows from the water pump outlet and into the engine block. In the engine block, the coolant
circulates through the water jackets surrounding the cylinders where it absorbs heat.
The coolant then flows through the cylinder head gasket openings and into the cylinder heads. In the
cylinder heads, the coolant flows through the water jackets surrounding the combustion chambers and
valve seats, where it absorbs additional heat.
From the cylinder heads, the coolant flows to the thermostat. The flow of coolant will either be stopped at
the thermostat until the engine reaches normal operating temperature, or it will flow through the
thermostat and into the radiator where it is cooled. At this point, the coolant flow cycle is completed.
Efficient operation of the cooling system requires proper functioning of all cooling system components.
The cooling system consists of the following components:
Page 44
2001 Chevrolet Cavalier Restoration Kit
Coolant
The engine coolant is a solution made up of a 50-50 mixture of DEX-COOL and suitable drinking water.
The coolant solution carries excess heat away from the engine to the radiator, where the heat is
dissipated to the atmosphere. |
Radiator
The radiator is a heat exchanger. It consists of a core and two tanks. The aluminum core is a tube and fin
crossflow design that extends from the inlet tank to the outlet tank. Fins are placed around the outside of
the tubes to improve heat transfer to the atmosphere.
The inlet and outlet tanks are a molded, high temperature, nylon reinforced plastic material. A high
temperature rubber gasket seals the tank flange edge to the aluminum core. The tanks are clamped to
the core with clinch tabs. The tabs are part of the aluminum header at each end of the core.
The radiator also has a drain cock located in the bottom of the left hand tank. The drain cock unit includes
the drain cock and drain cock seal.
The radiator removes heat from the coolant passing through it. The fins on the core transfer heat from the
~ coolant passing through the tubes. As air passes between the fins, it absorbs heat and cools the coolant.
Pressure Cap
The pressure cap seals the cooling system. It contains a blow off or pressure valve and a vacuum or
atmospheric valve. The pressure valve is held against its seat by a spring, which protects the radiator
from excessive cooling system pressure. The vacuum valve is held against its seat by a spring, which
permits opening of the valve to relieve vacuum created in the cooling system as it cools off. The vacuum,
if not relieved, might cause the radiator and/or coolant hoses to collapse.
The pressure cap allows cooling system pressure to build up as the temperature increases. As the
pressure builds, the boiling point of the coolant increases. Engine coolant can be safely run at a
temperature much higher than the boiling point of the coolant at atmospheric pressure. The hotter the
coolant is, the faster the heat transfers from the radiator to the cooler, passing air.
‘The pressure in the cooling system can get too high. When the cooling system pressure exceeds the
rating of the pressure cap, it raises the pressure valve, venting the excess pressure. |
As the engine cools down, the temperature of the coolant drops and a vacuum is created in the cooling
system. This vacuum causes the vacuum valve to open, allowing outside air into the surge tank. This
equalizes the pressure in the cooling system with atmospheric pressure, preventing the radiator and
coolant hoses from collapsing. |
Coolant Recovery System
The coolant recovery system consists of a plastic coolant recovery reservoir and overflow tube. The
recovery reservoir is also called a recovery tank or expansion tank. It is partially filled with coolant and is
connected to the radiator fill neck with the overflow tube. Coolant can flow back and forth between the
radiator and the reservoir.
In effect, a cooling system with a coolant recovery reservoir is a closed system. When the pressure in the
cooling system gets too high, it will open the pressure valve in the pressure cap. This allows the coolant,
which has expanded due to being heated, is allowed to flow through the overflow tube and into the
recovery reservoir. As the engine cools down, the temperature of the coolant drops and a vacuum is
created in the cooling system. This vacuum opens the vacuum valve in the pressure cap, allowing some
of the coolant in the reservoir to be siphoned back into the radiator. Under normal operating conditions,
no coolant is lost. Although the coolant level in the recovery reservoir goes up and down, the radiator and
cooling system are kept full. An advantage to using a coolant recovery reservoir is that it eliminates
Page 45
2001 Chevrolet Cavalier Restoration Kit
almost all air bubbles from the cooling system. Coolant without bubbles absorbs heat much better than
coolant with bubbles.
Air Baffles and Seals
The cooling system uses deflectors, air baffles and air seals to increase cooling system capability.
Deflectors are installed under the vehicle to redirect airflow beneath the vehicle and through the radiator
to increase engine cooling. Air baffles are also used to direct airflow through the radiator and increase
cooling capability. Air seals prevent air from bypassing the radiator and A/C condenser, and prevent
recirculation of hot air for better hot weather cooling and A/C condenser performance.
Water Pump
The water pump is a centrifugal vane impeller type pump. The pump consists of a housing with coolant
inlet and outlet passages and an impeller. The impeller is mounted on the pump shaft and consists of a
series of flat or curved blades or vanes on a flat plate. When the impeller rotates, the coolant between the:
vanes is thrown outward by centrifugal force.
The impeller shaft is supported by one or more sealed bearings. The sealed bearings never need to be
lubricated. Grease cannot leak out, dirt and water cannot get in as long as the seal is not damaged or
worn. | |
The purpose of the water pump is to circulate coolant throughout the cooling system. The water pump is
driven by the crankshaft via the drive belt.
Thermostat
The thermostat is a coolant flow control component. It's purpose is to help regulate the operating
temperature of the engine. It utilizes a temperature sensitive wax-pellet element. The element connects to
a valve through a small piston. When the element is heated, it expands and exerts pressure against the
small piston. This pressure forces the valve to open. As the element is cooled, it contracts. This
contraction allows a spring to push the valve closed.
When the coolant temperature is below the rated thermostat opening temperature, the thermostat valve
remains closed. This prevents circulation of the coolant to the radiator and allows the engine to warm up.
After the coolant temperature reaches the rated thermostat opening temperature, the thermostat valve will
open. The coolant is then allowed to circulate through the thermostat to the radiator where the engine
heat is dissipated to the atmosphere. The thermostat also provides a restriction in the cooling system,
after it has opened. This restriction creates a pressure difference which prevents cavitation at the water
pump and forces coolant to circulate through the engine block.
Engine Oil Cooler
The engine oil cooler is a heat exchanger. It is located inside the left side end tank of the radiator. The
engine oil temperature is controlled by the temperature of the engine coolant that surrounds the oil cooler
in the radiator.
The engine oil pump, pumps the oil through the engine oil cooler line to the oil cooler. The oil then flows
through the cooler where the engine coolant absorbs heat from the oil. The oil is then pumped through
the oil cooler return line, to the oil filter, to the engine block oil system.
Transmission Oil Cooler
The transmission oil cooler is a heat exchanger. It is located inside the right side end tank of the radiator.
The transmission fluid temperature is regulated by the temperature of the engine coolant in the radiator.
The transmission oil pump, pumps the fluid through the transmission oil cooler line to the transmission oil
cooler. The fluid then flows through the cooler where the engine coolant absorbs heat from the fluid. The
fluid is then pumped through the transmission oil cooler return line, to the transmission.
Page 46
2001 Chevrolet Cavalier Restoration Kit
Engine Electrical
Fastener Tightening Specifications
Negative Cable Terminal Bolt
Positive Cable Terminal Bolt
Side Terminal Adapter
Bolts 2.2L (L61)
Bolt-Lower 2.2L (LN2)
Bolt-Upper 2.2L (LN2)
Bolt 2.4L (LD9)
Battery Cable Ground Stud
Battery Cable to Starter Solenoid Nut
Nut | |
Motor Bolts 2.2L (L61)
Motor Bolt 2.2L (LN2)
tarter Motor Bolt 2.4L (LD9)
tarter Motor Solenoid S Terminal Nut
Harness Retainer Nut
Battery Usage
.2L 4cyl (LN2, L61)
M Part Number
Cranking Amperage (CCA)
Capacity
Model Number
AL 4cyl (LD9)
M Part Number
Cranking Amperage (CCA)
Capacity
Model Number
11 Ib ft
11 lb ft
11 lb ft
13 Ib ft
37 Ib ft
22 Ib ft
37 Ib ft
18 lb ft
13 lb ft
13 Ib ft
30 Ib ft
37 Ib ft
32 Ib ft
27 16 п
13 Ib ft
19001806
525
90 min.
75-5YR
19001807
- 600
90 min.
75-6YR
LN2, LD9
Generator Model CS130D _
[Rated Output 105 A
Load Test Output 73 A
Page 47
2001 Chevrolet Cavalier Restoration Kit
Battery Description and Operation
Caution
Batteries produce explosive gases, contain corrosive acid, and supply levels of electrical current
high enough to cause burns. Therefore, to reduce the risk of personal injury when working near a
battery:
®
Always shield your eyes and avoid leaning over the battery whenever possible.
Do not expose the battery to open flames or sparks.
Do not allow the battery electrolyte to contact the eyes or the skin. Flush immediately and
thoroughly any contacted areas with water and get medical help.
Follow each step of the jump starting procedure in order.
Treat both the booster and the discharged batteries carefully when u
cables.
ADAN
GER/POISON
—-
и E
po Qi ES
№ SHIELD E 1 SULFURIC
EYES NO ACID —
EXPLOSIVE i * SPARKS i CAN CAUSE
GASES cancause Ne FLAMES i BLINDNESS OR
BLINDNESS OR INJURY e SMOKING SEVERE BURNS
FLUSH EYES GET
IMMEDIATELY MEDICAL
WITH WATER HELP FAST
KEEP OUT OF THE REACH OF CHILDREN.
DO NOT TIP. DO NOT OPEN BATTERY!
A
X
Pb
sing the jumper
The maintenance free battery is standard. There are no vent plugs in the cover. The battery is completely
sealed except for two small vent holes in the side. These vent holes allow the small amount of gas that is
produced in the battery to escape.
The battery has three functions as a major source of energy:
Engine cranking
Voltage stabilizer
Alternate source of energy with generator overload.
Page 48
2001 Chevrolet Cavalier Restoration Kit
The battery specification label (example below) contains information about the following:
e The test ratings
e The original equipment catalog number
e The recommended replacement model number
CATALOG NO.
1819
CCA LOAD TEST
770 380
REPLACEMENT MODEL
100 — 6YR
A battery has 2 ratings:
e Reserve capacity
e Cold cranking amperage
When a battery is replaced use a battery with similar ratings. Refer to the battery specification label on
the original battery or refer to Battery Usage .
Reserve Capacity
Reserve capacity is the amount of time in minutes it takes a fully charged battery, being discharged at a
constant rate of 25 amperes and a constant temperature of 27°C (80°F) to reach a terminal voltage of
10. 5 У. Refer to Battery Usage for the reserve capacity rating of the original equipment battery.
Cold Cranking Amperage
The cold cranking amperage is an indication of the ability of the battery to crank the engine at cold
temperatures. The cold cranking amperage rating is the minimum amperage the battery must maintain for
30 seconds at -18°C (0°F) while maintaining at least 7.2 volts. Refer to Battery Usage for the cold
cranking amperage rating for this vehicle.
Circuit Description
The battery positive terminal supplies Battery Positive voltage to the under hood fuse block and the rear
fuse block. The under hood fuse block provides a cable connection for the generator and a cable
connection for the starter.
The battery negative terminal is connected to chassis ground G305 and supplies ground for the AD
converter in the DIM.
Starting System Description and Operation
The PG-260 F1 and PG-260L are non-repairable starter motors. They have pole pieces that are arranged
around the armature. Both solenoid windings are energized. The pull-in winding circuit is completed to the
ground through the starter motor. The windings work together magnetically to pull and hold in the plunger.
The plunger moves the shift lever. This action causes the starter drive assembly to rotate on the armature
shaft spline as it engages with the flywheel ring gear on the engine. Moving at the same time, the plunger
Page 49
2001 Chevrolet Cavalier Restoration Kit
also closes the solenoid switch contacts in the starter solenoid. Full battery voltage is applied directly to
the starter motor and it cranks the engine.
As soon as the solenoid switch contacts close, current stops flowing thorough the puli-in winding because
battery voltage is applied to both ends of the windings. The hold-in winding remains energized; its
magnetic field is strong enough to hold the plunger, shift lever, starter drive assembly, and solenoid
switch contacts in place to continue cranking the engine. When the engine starts, pinion overrun protects
the armature from excessive speed until the switch is opened.
When the ignition switch is released from the START position, the START relay opens and battery
voltage is removed from the starter solenoid S terminal. Current flows from the motor contacts through
both windings to the ground at the end of the hold-in winding. However, the direction of the current flow
through the pull-in winding is now opposite the direction of the current flow when the winding was first
energized. a. | | |
The magnetic fields of the pull-in and hold-in windings now oppose one another. This action of the
windings, along with the help of the return spring, causes the starter drive assembly to disengage and the
solenoid switch contacts to open simultaneously. As soon as the contacts open, the starter circuit is
turned off.
Circuit Description
When the ignition switch is placed in the Start position 12 volts is supplied through the Park/Neutral
Position Switch to the S terminal of the Starter Solenoid. Ground is found through the engine block.
Charging System Description and Operation
Generator
The generator features the following major components:
The delta stator
The rectifier bridge
The rotor with slip rings and brushes
A conventional pulley |
Dual internal fans
The regulator
The pulley and the fan cool the slip ring and the frame.
The generator features permanently lubricated bearings. Service should only include tightening of mount
components. Otherwise, replace the generator as a complete unit. |
Regulator
The voltage regulator controls the rotor field current in order to limit the system voltage. When the field
current is on, the regulator switches the current on and off at a rate of 400 cycles per second in order to
perform the following functions: |
e Radio noise control
e Obtain the correct average current needed for proper system voltage control
At high speeds, the on-time may be 10 percent with the off-time at 90 percent. At low speeds, the on-time
may be 90 percent and the off-time 10 percent. |
Circuit Description
The generator provides voltage to operate the vehicle's electrical system and to charge its battery. A
magnetic field is created when current flows through the rotor. This field rotates as the rotor is driven by
Page 50
2001 Chevrolet Cavalier Restoration Kit
the engine, creating an AC voltage in the stator windings. The AC voltage is converted to DC by the
rectifier bridge and is supplied to the electrical system at the battery terminal.
When the engine is running, the generator turn-on signal is sent to the generator from the PCM, turning
on the regulator. The generator's voltage regulator controls current to the rotor, thereby controlling the
output voltage. The rotor current is proportional to the electrical pulse width supplied by the regulator.
When the engine is started, the regulator senses generator rotation by detecting AC voltage at the stator
through an internal wire. Once the engine is running, the regulator varies the field current by controlling
the pulse width. This regulates the generator output voltage for proper battery charging and electrical
system operation. The generator F terminal is connected internally to the voltage regulator and externally
to the PCM. When the voltage regulator detects a charging system problem, it grounds this circuit to
signal the PCM that a problem exists. The PCM monitors the generator field duty cycle signal circuit. The
system voltage sense circuit receives battery positive voltage that is Hot At All Times through a fuse link
that is connected to the starter motor. This voltage is used by the regulator as the reference for system
voltage control. | | | |
Charging System Indicator
The IPC illuminates the charge indicator in the message center when the following occurs:
e The PCM detects that the generator output is less than 11 volts or greater than 16 volts. The IPC
receives a class 2 message from the PCM requesting illumination.
e The IPC determines that the system voltage is less than 11 volts or greater than 16 volts. The
IPC receives a class 2 message from the body control module (BCM) indicating the system
voltage. | -
e The IPC performs the displays test at the start of each ignition cycle. The indicator illuminates for
approximately 3 seconds.
e The ignition is on, with the engine off.
Engine Controls
Engine Controls - 2.2L (LN2)
Firing Order | 1-3-4-2
Spark Plug Wire Resistance | 12,000 ohms per ft
Spark Plug Torque 18 N-m 13 Ib ft
Spark Plug Gap | 1.016 mm 0.040 in
Spark Plug Type 41-948 [AC plug type]
Fastener Tightening Specifications
. Cable Bracket Bolts | 89 lb in
. Pedal Nuts 22 lo ft
Cleaner Outlet Duct Clam 44 lb in
Cleaner Outlet Resonator Clam 44 lb in
Cleaner Outlet Resonator Mounting Screws 89 Ib in
Cleaner Resonator Bracket-Side Nut 89 Ib in
Cleaner Resonator Bracket-U Nut 18 lb ft
Page 51
2001 Chevrolet Cavalier Restoration Kit
ir Cleaner Resonator Bracket Bolt 25 N-m 18 Ib ft
CKP Sensor Bolts 8 N-M 71 Ibin
CMP Sensor Bolts 10 N-m 89 Ib in
Engine Coolant Sensor 20 N-m 15 lb ft
Engine Oil Pressure Sensor 12 N-m 106 Ib in
EVAP Canister Purge Valve Mounting Bracket Bolt 8 N-m 71 Ib in
EVAP Canister Retainer Bolt 10 N-m 89 Ib in
Exhaust Shield Bolt 2 N-m 18 Ib in
Exhaust Shield Nuts 1 N-m 9 Ib in
Flex Duct Clamps 5 N-m 44 lb in
|Fuel Pipe Mounting Bolts 6 N-m 53 Ib in
Fuel Filler Hose Clamp 3 N-m 27 lb in
Fuel Filter Fitting 27 N-m 20 lb ft
Fuel Pressure Regulator Attaching Screw 9.5 N-m 84 Ib in
Fuel Rail Attaching Bolts 25 N-m 18 lb ft
Fuel Return Pipe to Fuel Pressure Regulator 33 N-m 24 |b ft
Fuel Tank Retaining Strap Bolts 35 N-m 26 Ib ft
Headlamp Assembly Retaining Screws 7 Nm 61 lb in
Horn Attaching Bolt 10 N-m 89 lb in
HO2S 2 41 N-m 30 Ib ft
ICM Screws 4 N-m 35 Ib in
Idle Air Control Valve 3 N-m 27 Ibin
Ignition Coil Screws 4 N-m 35 Ib in
Knock Sensor 19 N-m 14 Ib ft
[Lower Air Cleaner Mounting Bolt 6 N-m 53 Ib in
MAP Sensor Attaching Screw 6.5 N-m 53 Ib in
025 1 41 N-m 30 Ib ft
PCM Attaching Bolts 10 N-m 89 Ibin .
PCM Electrical Connector Screws 8 N-m 71 Ib in
Resonator Attaching Bolt 7 N-m 61 Ib in
Separator and Solenoid Attaching Bolts 8 N-m 71 Ib in
Throttle Body Attaching Bolts 10 N-m 89 Ib in
TP Sensor Mounting Screws 2 N-m 18 Ib in
Upper Air Cleaner Cover Screws 3 N-m 27 Ib in
Fuel System Specifications
Use regular unleaded gasoline rated at 87 octane or higher. It is recommended that the gasoline meet
specifications which have been developed by the American Automobile Manufacturers Association
(AAMA) and endorsed by the Canadian Motor Vehicle Manufacturers Association for better vehicle
performance and engine protection. Gasoline meeting the AAMA specification could provide improved
driveability and emission control system performance com pared to other gasolines. For more information,
write to: American Automobile Manufacturer's Association, 7430 Second Ave, Suite 300, Detroit MI
48202.
Be sure the posted octane is at least 87. If the octane is less than 87, you may get a heavy knocking
noise when you drive. If the knocking is bad enough, the knocking can damage your engine.
Page 52
2001 Chevrolet Cavalier Restoration Kit
If you are using fuel rated at 87 octane or higher and you hear heavy knocking, your engine needs
service. But do not worry if you hear a little pinging noise when you are accelerating or driving up a hill.
That is normal, and you do not have to buy a higher octane fuel to get rid of the pinging. However, if there
is a heavy, constant knock, that means you have a problem. |
Notice
Your vehicie was not designed for fuel that contains methanol. Do not use methanol fuel which can
corrode metal parts in your fuel system and also damage plastic and rubber parts. This kind of damage
would not be covered under your warranty.
If your vehicle is certified to meet California Emission Standards, indicated on the under hood emission
control label, your vehicle is designed to operate on fuels that meet California specifications. If such fuels
are not available in states adopting California emissions standards, your vehicle will operate satisfactorily
on fuels meeting federal specifications, but emission control system performance may be affected. The
malfunction indicator lamp on your instrument panel may turn ON and/or your vehicle may fail a smog-
check test. If this occurs, return to your authorized dealer for diagnosis to determine the cause of failure.
In the event there is a determination that the cause of the condition is the type of fuels used, repairs may
not be covered by your warranty. |
Some gasolines that are not reformulated for low emissions may contain an octane-enhancing additive
called methylcyclopentadienyl manganese tricarbonyl (MMT). Ask your service station operator whether
or not the fuel contains MMT.
Electronic Ignition (El) System Description
System Operation a
The electronic ignition (El) system consists of the following:
Two ignition coils
The ignition control (IC) module
The crankshaft position (CKP) sensor
The camshaft position (CMP) sensor
The powertrain control (PCM) module
In this system the secondary windings of each coil feed two spark plugs, and neither end of the windings
are grounded. The engine cylinders are paired in opposites, i.e. cylinders 1 and 4, and 2 and 3. Each pair
“is on top dead center at the same time. When a coil discharges both plugs fire at the same time to
complete a series circuit. The cylinder on the compression stroke is said to be the event cylinder, the
cylinder on the exhaust stroke the waste cylinder. The waste cylinder requires very little of the available
energy to fire the spark plug, the event cylinder will use most of the energy. This same process will be
repeated when the respective pair of cylinders are on the opposite stroke. This method of ignition is
known as waste spark ignition.
It is possible in a waste spark ignition system for a spark plug to fire even if the spark plug's companion
plug is disconnected. The disconnected plug wire acts as one plate of a capacitor, with the engine being
the other plate. These two capacitor plates are charged as the spark jumps across the gap of the
connected spark plug. The plates are then discharged as the secondary energy is dissipated in an
oscillating current across the gap of the spark plug that is still connected. Secondary voltage
requirements are very high with part of the circuit open, but the ignition coil has enough reserve energy to
fire the connected plug at idle. Under high load it is possible neither plug will fire resulting in a severe
misfire. In order to properly control the ignition timing, the PCM relies on the following information:
The engine load (manifold pressure or vacuum)
The engine coolant temperature
The intake air temperature
The crankshaft position
Page 53
2001 Chevrolet Cavalier Restoration Kit
The engine speed (RPM)
The knock sensor
e The TP sensor
System Components
The Crankshaft Position (CKP) Sensor
This system uses a magnetic CKP sensor, mounted remotely from the ICM, which protrudes into the
block within approximately 0.050 inches from the crankshaft reluctor. The graphic illustrates a typical
sensor in relationship to the crankshaft reluctor. The reluctor is a special wheel which is cast into the
crankshaft with 7 slots machined into the wheel, 6 of which are equally spaced (60 degrees apart). A
seventh slot is spaced 10 degrees from one of the other slots and serves to generate sync-pules. As the
reluctor rotates as part of the crankshaft, the slots change the magnetic field of the sensor, creating an
induced voltage pulse. This signal is known as the 7x or low resolution signal because it occurs 7 times
per crankshaft resolution. The PCM uses this signal to determine the speed and position of the
crankshaft. The 7x reference signal is also used for fuel injector activation and ignition coil sequencing.
Ignition Coils
Two separate coils are mounted to the ignition coil assembly. Each coil provides the spark for two plugs
simultaneously (waste spark distribution). Each coil can also be replaced separately. |
Ignition Control Module (ICM)
The ICM receives the ignition control (IC) signals from the powertrain control module (PCM) which in turn
triggers the corresponding ignition coils. Since the PCM controls spark timing and ignition control during
crank and run, there is no bypass mode. The ICM is not repairable. When an ICM is replaced, transfer the
remaining components to the new module.
Air Intake System Description
The air induction system draws outside air through a forward mounted air cleaner. The air cleaner is
remotely mounted. The air enters the engine by flowing in through the intake duct into the lower air
cleaner, through the air filter, out of the upper air cleaner, through the flex duct, into the air cleaner outlet
resonator, and into the throttle body and the intake manifold. The air is then directed into the intake
runners, the cylinder head and into the cylinders. A remotely mounted resonator as well as a resonator
mounted on the throttle body help to dampen the noise caused by drawing air into the engine.
Page 54
2001 Chevrolet Cavalier Restoration Kit
Engine Controls - 2.4L (LN9)
Ignition System Specifications
Firing Order
1-3-4-2
Spark Plug Torque 18 N'm 13 Ib ft
Spark Plug Gap 1.27 mM 0.050 in
Spark Plug Type
41-963 [AC plug type]
Fastener Tightening Specifications
Accelerator Cable Bracket Bolts 89 Ib in
Accelerator Pedal Nuts 30 N-m 25 Ib ft
Air Cleaner Outlet Duct Clamps 5 N-m 44 lb in
Air Cleaner Outlet Resonator Clamp 5 N-m 44 lb in
Air Cleaner Outlet Resonator Mounting Screws 10 N-m 89 lb in
CKP Sensor Bolts 10 N-m 89 lb in
CMP Sensor Bolts 15 N-m 11 Ib ft
Engine Coolant Sensor 20 N-m 15 Ib ft
EVAP Canister Purge Valve Mounting Bracket Nut 8N-m 71 Ib in
EVAP Canister Retainer Bolt 10 N-m 89 Ib in
Exhaust Shield Bolt 2.0 N-m 18 Ib in
Exhaust Shield Nut 1.0 N-m 9 Ib in
[Fuel Feed Pipe to Fuel Rail 33 N-m 24 lb ft
Fuel Filler Hose Clamp 3 N-m 27 lb in
Fuel Filter Fitting 27 N-m 20 Ib ft
Fuel Pipe Mounting Bolts 6 N-m 53 lb in
Fuel Pipe Retainer Bolts 12 N-m 106 Ib in
Fuel Pressure Regulator Attaching Screw 9.5 N-m 84 lb in
Fuel Rail Attaching Bolts 26 N-m 19 Ib ft
Fuel Return Pipe Bracket Screw 9.5 N-m 84 lb in
Fuel Tank Retaining Strap Bolts 35 N-m 26 lb ft
Headlamp Assembly Retaining Screws 7 Nm 61 Ib in
Horn Attaching Bolt 10 N'm 89 Ib in
HO2S 2 41 №т 30 Ib ft
ICM Cover Bolts 22 N-m 16 |b ft
ICM Screws 4 N-m 35 Ib in
Idle Air Control Valve 3 N-m 27 lb in
Ignition Coil Housing Screws 4 N-m 35 Ib in
Knock Sensor 25 N:m 19 Ib ft
Map Sensor Replacement 6.5 N-m — 57 Ibin
Page 55
2001 Chevrolet Cavalier Restoration Kit
02S 1 41 N-m 30 Ib ft
PCM Attaching Bolts | 10 N-m 89 Ib in
PCM Electrical Connector Screws | 8Nm | 71lbin
Resonator Attaching Bolt 7 N-m 61 Ib in
Throttle Body Attaching Bolts 10 N-m 89 lb in
TP Sensor Mounting Screws 2 N-m 18 Ib in
Upper Air Cleaner Cover Screws 3 N-m 27 Ib in
Fuel System Specifications
See Fuel System Specifications for 2.2L Engine above.
Electronic Ignition (El) System Description
See Electronic Ignition (El) System Description for 2.2L Engine above.
Air Intake System Description
See Air Intake System Description for 2.2L Engine above.
Exhaust System
Fastener Tightening Specifications
Manifold Heat Shield Bolt (2.4 L) | 10 Ib ft
Manifold Nut 115 1b in
Manifold Pipe Bolt | 33 Ibft
Decoupler to Exhaust Manifold Bolt (2.4 L) 26 Ib ft
Outlet Hose Nut (2.2 L) | a | 181bt
ntermediate Pipe Bolt | 22 Ib ft
Hanger Bolt 12 Ib ft
Exhaust System Description
important
Use of non-OEM parts may cause driveability concerns.
The exhaust system carries exhaust gases, treated by the catalytic converter, through a resonator, if
applicable and into the exhaust muffler where exhaust noise is lessened.
In order to secure the exhaust pipe to the exhaust manifold, a flange and seal-joint coupling is utilized.
The exhaust system may utilize a slip-joint coupling design with a clamp and a U-bolt or a flange
connection with a gasket.
Exhaust hangers and rubber insulators help to support the weight of the exhaust pipe along with
insulating any exhaust system vibration, rattle, or noise.
Exhaust hangers also space the exhaust system away from the underbody of the vehicle and allows the
exhaust system to expand as the exhaust system warms up.
Exhaust heat shields are used to protect the body and other components from damage due to the heat
from the exhaust system.
Page 56
2001 Chevrolet Cavalier Restoration Kit
The exhaust system may be comprised of the following components:
~ Exhaust manifold
Exhaust pipes
Catalytic converters
Exhaust muffler
Exhaust resonator, if equipped
Exhaust tail pipe, if equipped
Exhaust hangers |
Exhaust heat shields
Resonator
. a a e. a .
Some exhaust systems are equipped with a resonator. The resonator, located either before or after the
muffler, allows the use of mufflers with less back pressure. Resonators are used when vehicle
characteristics require specific exhaust tuning.
Catalytic Converter
The catalytic converter is an emission control device added to the engine exhaust system in order to
reduce hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) pollutants from the
exhaust gas. |
The catalytic converter is comprised of a ceramic monolith substrate, supported in insulation and housed
within a sheet metal shell. The substrate may be washcoated with 3 noble metals:
o Platium (Pt)
e Palladium (Pd)
e Rhodium (Rh)
The catalyst in the converter is not serviceable.
Muffler
The exhaust muffler reduces the noise levels of the engine exhaust by the use of tuning tubes. The tuning
tubes create channels inside the exhaust muffler that lower the sound levels created by the combustion of
the engine. | |
Page 57
2001 Chevrolet Cavalier Restoration Kit
Transmission/Transaxle Description and Operation
Manual Transmission - M86/M94 Getrag
Fastener Tightening Specifications
n/Fill PI ; 28 lb ft
ntermediate Shaft Bolts 74 lb ft
ront Transmission Mount | | 55 Ib ft
Cover Bolts | | 18 Ib ft
Transmission Mount 55 lb ft
Switch | 13 Ib ft
Gear 66 Ib ft
Bolts | 74 lb ft
Guide Bolts | 18 Ib ft
Mounting Bolts 18 lb ft
Sensor Bolt 8 lb ft
ransmission Bolts 18 Ib ft
Lubrication Specifications
Shim Size Specifications
0.0197 in
0.0217 in
0.0236 in
0.0256 in
0.0276 in
0.0295 in
0.0315 in
0.0335 in
0.0354 in
0.0374 in
0.0394 in
0.0413 in
0.0433 in
0.0453 in
0.0473 in
0.0493 in
0.0512 in
0.0531 in
Page 58
2001 Chevrolet Cavalier Restoration Kit
Automatic Transmission Shift Lock Control Description and Operation
The automatic transmission shift lock control system is a safety device that prevents an inadvertent shift
out of PARK when the engine is running. The driver must press the brake pedal before moving the shift
lever out of the PARK position. The system consists of thew following components:
e The automatic transmission shift lock control solenoid
e The body control module (BCM)
e The powertrain control module (PCM)
With the ignition in the ON position, battery positive voltage is supplied to the automatic transmission shift
lock control solenoid. The automatic transmission shift lock control solenoid receives a ground from the
BCM. When the automatic transmission shift lock control solenoid is energized, the shift lever
mechanically locked in the PARK position. When the driver presses the brake pedal the PCM sends a
class 2 serial data message to the BCM. The BCM turns OFF the ground control circuit and this de-
energizes the automatic transmission shift lock control solenoid. When the automatic transmission shift
lock control solenoid is de-energized, the shift lever may be moved out of the PARK position. The BCM
determines transaxle shift lever position through a class 2 serial data message from the PCM. The PCM
receives inputs from the park/neutral position switch and determines shift lever position. When the BCM
receives this information and determines that the shift lever is out of the PARK position, the automatic
transmission shift lock control solenoid ground is opened.
Automatic Transaxle - 3T40
181bft
Parking Lock Bracket to Case
Case Cover to Case 4 | M8x1.25x45
Case Cover to Case 63 4 | M8x1.25x55 | 24 N-m| 18 Ib ft
Case Cover to Case 61 1 | M8x1.25x40 | 24 N-m | 18lb ft
“Case Cover to Case 60 7 | M8x1.25x25 | 24 N-m | 18 Ib ft
Case Cover to Case 64 2 | М8х1.25х25 | 24 №т | 18 Ib ft
Case Side Cover -- -- - 20 N-m | 151b ft
Case to Drive Sprocket Support 114 4 | M8x1.25x24 | 24 N-m | 18lb ft
Control Valve Body Cover to Case 36 11 | M8x1.25x16 | 11 N-m | 8b ft
Converter Shield -- -- -- 10 №т | 18lb ft
Cooler Connector to Case 17 2 | 1/4-18NPSF | 38 N-m | 28 Ib ft
Cooler Pipes at Case -- -- -- 22 №т | 1616 #
Cooler Pipes at Radiator -- -- -- 27 №т | 20Ib ft
Flywheel to Torque Converter -- -- — 62 N-m | 46 Ib ft
Intermediate Servo Cover to Case 141 4 | M6x1.0x20 |11 N-m| 8Ibft
Line Pressure Plug 405 1 | 1/8-27NPTF | 11 N.m | 8Ib ft
Manual Detent Spring Assembly to Case 418 1 | M6x1.0x10 111 N.m| 8lbft
Oil Feed Tube Bolts -- — -- 14 N-m | 124 Ib in
Oil Pan to Case - 36 16 | M8x1.25x16 | 10 N-m | 89 Ib in
Oil Pressure Switch to Valve Body 338 1 | 1/8-27NPTF |11 N-m | 8b ft
Park/Neutral Position Switch to Case -- -- -- 24 N-m | 1816 #
712 2 | M8x1.25x25 | 24 N-m | 18lb ft
Page 59
2001 Chevrolet Cavalier Restoration Kit
[Pipe Retainer to Case 142 2 | M6x1.0x15 [24 N-m| 18lbft
Pressure Switch Assembly Bolts — - | — 12 N-.m | 106 Ib in
Pump Cover to Case Cover 44 1 | М8х1.25х130 | 24 №т | 18 Ib ft
Pump Cover to Valve Cover 8 4 | M6x1.0x25 | 11 N-m 8 |b ft
Pump Cover to Valve Body 41 3 | M6x1.0x90 {11 N'm| 8Ibft
Shift Lever to Transmission Nut -- -- -- 20 №т | 151b ft
Speed Sensor/Govenor Cover to Case 8 2 | M6x1.0x25 | 11 N-m | 97 6 п
TCC Solenoid Valve to Valve Body 334 1 | M6x1.0x16 |11 N-m | 97lbin
Thrid Clutch Pressure Switch to Valve Body 335 1 | 1/8-27NPTF | 11 №т | 97 6 п
Transmission to Engine Mount Bolts — - - 96 N-m| 71lbft
TV Cable to Case N/A 1 | M6x1.0x16 | 9N-m | 80lbin
Valve Body to Case 43 1 | M8x1.25x85 |24 N-m | 18lb ft
Valve Body to Case Cover 24 9 | M6x1.0x45 [11 N-m| 8Ibft
Valve Body to Case Cover 40 2 | M6x1.0x65.0 [11 N'm| 8Ib ft
Valve Body to Driven Sprocket Support 42 1 | M8x1.25x65 | 24 №т | 18 Ib ft
Transmission General Specifications
RPO Codes
MD9
Production Location
Ypsilanti, Michigan
Vehicle Platform (Engine/Transmission)
Usage |
J
Transmission Drive
Transverse Mounted Front Wheel Drive
Maximum Engine Torque
270 N-m (200 Ib ft)
1st Gear Ratio 2.840:1
2nd Gear Ratio 1.600:1
3rd Gear Ratio 1.000:1
Reverse 2.067:1
Torque Converter Size (Diameter of Torque Converter Turbine) 245 mm
Pressure Taps
Line Pressure
Governor Pressure
Transmission Fluid Type
DEXRONO III
Transmission Type: 3
Three Forward Gears
Transmission Type: T
Transverse Mount
Transmission Type: 40
Product Series
Position Quadrant
P,R,N, D, 2, 1
Case Material
Die Cast Aluminum
Transmission Weight Dry
65.7 kg (144 Ibs)
Transmission Weight Wet
73.1 kg (161 Ibs)
Maximum Trailer Towing Capacity
487 kg (1,000 Ibs)
Maximum Gross Vehicle Weight (GVW)
2,318 kg (5,100 Ibs)
Page 60
2001 Chevrolet Cavalier Restoration Kit
‘Ratios
Chain | Final Drive Effective (Overall)
33/37 2.84 | 3.18
33/37 3.06 3.43
33/37 3.33 | | 3.73
35/35 2.84 2.84
35/35 3.06 3.06
35/35 3.33 3.33
37/33 | | 2.84 | 2.53
37/33 3.06 2.73
37/33 | 3.33 2.97
Bottom Pan Removal 3.8 liters 4 quarts
Complete Overhaul | 6.6 liters 7 quarts
Dry | 8.5 liters 9 quarts
(measurements are approximate)
Direct Clutch — Applied -- - Applied ~~ = =
Interm. Band | — -- -- Applied -- -- Applied --
Forward Clutch -- -- Applied | Applied | Applied | Applied | Applied | Applied
Lo-Reverse Clutch -- Applied - - - — — Applied
Roller Clutch -- -- Holding -- -- *Holding — Holding
*May not be holding in Intermediate (D2), may stay in 2nd gear when vehicle is stopped.
Shift Speed
ehicle Series
Displacement
RPO Code
VIN Code
| Axle Ratio
Drive Ratio
Sprocket Teeth
Page 61
2001 Chevrolet Cavalier Restoration Kit
11 mph
Minimum Throttle 1-2 Upshift (18 km/h)
41 mph
Wide Open Throttle 1-2 Upshift (66 oni)
21 mph
Minimum Throttle 2-3 Upshift (3a km/h)
. 76 mph
Wide O Throttle 2- |
ide Open Throttle 2-3 Upshift (122 km/h)
Minimum TCC Apply 35
. IN/V Ratio 40
Torque Converter K-Factor 203
Governor Pressure Switch N/A
Second Gear Pressure Switch N/A
Third Gear Pressure Switch N.O.
Direct Clutch Type .5 plate
Transmission Vent Type Elbow
Manual Valve Thermal Element No
e N/A = Not Available
e N.O. = Normally Open
ratings)
e N/V Ratio = Engine RPM to Vehicle Speed ratio in the third gear with TCC applied
e K-Factor = Torque converter numeric rating (combines stall speed and torque multiplication
Transmission General Description
The Hydra-Matic 3T40 transmission is a fully automatic unit for front wheel drive vehicles. The 3T40
provides three forward gear ranges and a reverse. Throttle opening controls the oil pressure and shift
points.
You can operate the transmission in any one of the following six modes:
o P — Park position prevents the vehicle from rolling either forward or backward. For safety
reasons, use the parking brake in addition to the park position.
R -- Reverse allows the vehicle to be operated in a rearward direction.
N -- Neutral allows the engine to be started and operated while driving the vehicle. If necessary,
you may select this position in order to restart the engine with the vehicle moving.
e D -- Drive position is used for normal driving conditions. Drive position provides three gear ratios
plus a converter clutch operation. Downshifts are available for safe passing by depressing the
accelerator.
e 2 -- Manual second provides acceleration and engine braking. You may select this range at any
vehicle speed.
e 1 --Manual Low provides maximum engine braking. You may select this range at any vehicle
speed.
Page 62
2001 Chevrolet Cavalier Restoration Kit
Transmission Component and System Description
The 3T40 transmission consists primarily of the following components:
A four-element hydraulic torque converter
A compound planetary gear set
A dual sprocket and drive link assembly
Three multiple disc clutches
One roller clutch |
An intermediate band assembly
A valve body assembly
A vane type oil pump
~The electronic components of this unit are as follows:
A third clutch pressure switch
Torque converter clutch solenoid
Park/neutral position switch
Vehicle speed sensor assembly
Automatic Transaxle - 4T40-E/4T45-E
Fastener Tightening Specifications Unit Repair
Bottom Pan to Case -- M6 x 1.0 x 19.0 (Qty 12)
Case Cover 24 N-m 18 lb ft
Case Side Cover 20 N-m 15 lb ft
Channel Plate to Case -- M6 x 1.0 x 28.0 (Qty 6) 12 N-m | 106 Ib in
Channel Plate to Case -- M6 x 1.0 x 63.0 (Qty 2) 12 N-m | 106 Ib in
Channel Plate to Driven Sprocket Support -- M6 x 1.0 x 28.0 (Qty 2) 14N-m | 124 Ib in
Clip, Wiring Harness -- M6 x 1.0 x 15.0 (Qty 1) 12N-m | 106 Ib in
Converter Shield 10 N-m | 181bft
Cooler Pipes at Case 8 N-m 71 Ib in
Cooler Pipes at Radiator 20-40 N-m| 15-30 Ib ft
Cover Assembly, Intermediate 4th Servo to Case -- M6 x 1.0 x 28.0 (Qty 3) 12N-m | 106 Ib in
Cover, Lo/Reverse Servo to Case -- M6 x 1.0 x 28.0 (Qty 3) 12N-m | 106 Ib in
Cover, Side to Case -- M8 x 1.25 x 28.0 (Qty 10) 20 N-m 15 Ib ft
“Cover, Side to Case (Stud) -- M8 x 1.25 x 28.0 (Qty 1) — 20 №т | 151b ft
Flywheel to Torque Converter 62 N-m 46 lb ft
Oil Check Plug 14 N-m | 124 Ib in
Oil Feed Tube Bolts 14 №т | 124 6 п
Oil Pan to Case 10 №т | 89lbin
Park/Neutral Position Switch to Case 24 N-m 18 Ib ft
Plug, Pipe -- 1/8-27 NPTF (Qty 2) 12N-m | 106 Ib in
Pressure Switch Assembly Bolts 12N-m | 106 Ib in
Pump, Valve Body, Channel Plate to Case -- M6 x 1.0 x 103.0 (Qty 1) 12 N-m | 106 Ib in
Page 63
2001 Chevrolet Cavalier Restoration Kit
Pump, Valve Body to Channel Plate -- M6 x 1.0 x 63.0 (Qty 1) 12N-m | 106 Ib in
Pump, Valve Body to Channel Plate -- M6 x 1.0 x 90.0 (Qty 6) 12N-m | 106 Ib in
Sensor, Input Speed -- M6 x 1.0 x 15.0 (Qty 1) 12N-m | 106 Ib in
Sensor, Output Speed (Stud) -- M6 x 1.0 x 15.0 (Qty 1) 12N-m | 106 Ib in
Shift Lever to Transmission Nut 20 N-m 15 lb ft
Spacer, Channel Plate to Driven Sprocket Support -- M6 x 1.0 x 70.0 (Qty 2) 14 N-m | 124 Ib in
Speed Sensor Housing to Case 11 N-m | 97 Ibin
Spring and Roller Assembly, Detent to Channel Plate -- M6 x 1.0 x 19.0 (Qty 1) 12 №т | 106 Ib in
Support Assembly, Drive Sprocket to Case -- M6 x 1.0 x 17.2 (Qty 6) 12N-m | 106 Ib in
ТЕР Switch, Valve Body, Channel Plate --M6 x 1.0 x 51.0 (Qty 3) 12 N-m | 106 Ib in
TFP Switch, Valve Body, Channel Plate -- M6 x 1.0 x 63.0 (Qty 1) 12N-m | 106 Ib in |
TFP Switch, Valve Body, Channel Plate to Case -- M6 x 1.0 x 90.0 (Qty 2) 12 N-m | 106 Ib in
Transmission to Engine Mount Bolts | 90 №т | 66lbft
Tube Assembly, Transmission Oil to Case -- M6 x 1.0 x 19.0 (Qty 2) 12N-m | 106 Ib in
Eros un Transmission Oil to Forward Clutch Support -- M6 x 1.0 x 19.0 12N-m | 106 lb in
Qty emo Transmission Oil to Lo/Reverse Servo Cover -- M6 x 1.0 x 19.0 12 N-m | 106 Ib in
TV Cable to Case 9 N-m 80 Ib in
Valve Body, Channel Plate to Case -- M6 x 1.0 x 90.0 (Qty 5) 12N-m | 106 Ib in
Valve Body, Channel Plate to Case -- M6 x 1.0 x 103.0 (Qty 2) 12N-m | 106 Ib in
Valve Body to Channel Plate -- M6 x 1.0 x 51.0 (Qty 5) 12N-m | 106 Ib in
Transmission General Specifications
RPO Codes
MN4 - 4T40-E
MN5 - 4T45-E
Production Location
Windsor, Ontario, Canada
Vehicle Platform
Engine/Transmission
Usage
J, N
Transmission Drive
Transverse Mounted Front Wheel Drive
Maximum Engine Torque
4T40-E 270 N-m (200 Ib ft)
4T45-E 290 N-m (215 Ib ft)
| 1-2 6,500 RPM
Maximum Shift Speed 2-3 6,500 RPM
3-4 6,500 RPM
1st Gear Ratio 2.960:1
2nd Gear Ratio 1.626:1
3rd Gear Ratio 1.000:1
4th Gear Ratio 0.681:1
Reverse 2.143:1
Torque Converter Size - Diameter of Torque Converter Turbine 245 mm
Page 64
2001 Chevrolet Cavalier Restoration Kit
Pressure Taps
Line Pressure
Transmission Fluid Type
DEXRONO III
Transmission Fluid Capacity - Approximate
Bottom Pan Removal: 6.5 L (6.9 gts)
Complete Overhaul: 9.0 L (9.5 ats)
Dry: 12.2 L (12.9 gts)
Transmission Type: 4
Four Forward Gears
Transmission Type: T
Transverse Mount
Transmission Type: 40
Product Series
Transmission Type: E
Electronic Controls
Position Quadrant
P, R, N, Overdrive, 3, 2, 1
Case Material
Die Cast Aluminum
Transmission Weight Dry
4140-Е 74.7 Ка (164 165)
4145-Е 75.1 kg (165.6 Ibs)
Transmission Weight Wet
4T40-E 85.0 kg (187 Ibs)
4T45-E 85.5 kg (188.5 Ibs)
Maximum Trailer Towing Capacity
487 kg (1,000 Ibs)
Maximum Gross Vehicle Weight (GVW)
Chain Final Drive — Effective - Overall
32/38 3.29 3.91
32/38 3.05 3.63
35/35 3.29 3.29
35/35 3.05 3.42
33/37 3.29 3.69
33/37 3.05 3.42
Bottom Pan Removal
6.5 liters 6.9 quarts
Complete Overhaul 9.0 liters 9.5 quarts
Dry 12.2 liters 12.9 quarts
Measurements are approximate.
Page 65
2001 Chevrolet Cavalier Restoration Kit
Range Reference
1-2 Shift Solenoid
-3 Shift Solenoid
Clutch
Roller Clutch
nt./4th
ON | ON |ON|OFF|OFF
OFF |OFF|OFF| ON
A | A”
ON
ON
A*
ОМ | OFF |OFF| ON (OFF | OFF | ON | OFF
OFF | OFF | ON (OFF | OFF | ON (OFF | OFF
A A | A”
H
Clutch
Clutch
nput Sprag
Clutch
Clutch
Band
Roller Clutch
e A= Applied
e H= Holding
e O = Overrunning
e ON =The solenoid is energized
e OFF = The solenoid is de-energized
e * = Applied with no load | |
e ™ =Manual SECOND-THIRD gear is only available above approximately 100 km/h (62 mph)
e =Manual FIRST-SECOND gear is only available above approximately 60 km/h (37 mph)
e Manual FIRST-THIRD gear is also possible at high vehicle speed as a safety feature
Shift Speed
WKR | LN2 |9[145] 21 | 18 | 25 1395] 30 | 25 1 67 | 30 | 115 | © 26
WBR| LD9 [9] 15 | 28 | 17 | 20 | 51 | 34 | 51 | 79 | 30 | 11 | & 22
Page 66
2001 Chevrolet Cavalier Restoration Kit
<A
Transmission General Description
The 4T40-E is a fully automatic front wheel drive electronically controlled transmission. The 4T40-E
provides four forward ranges including overdrive and one reverse gear range. The PCM controls shift
points by means of two shift solenoids. A vane type pump supplies the oil pressure. The PCM regulates
oil pressure by means of the Pressure Control Solenoid (PCS).
You can operate the transmission in any one of the following seven modes:
P -- Park position prevents the vehicle from rolling either forward or backward. For safety
reasons, use the parking brake in addition to the park position.
R -- Reverse allows the vehicle to be operated in a rearward direction.
N -- Neutral allows the engine to be started and operated while driving the vehicle. If necessary,
you may select this position in order to restart the engine with the vehicle moving. |
D -- Overdrive is used for all normal driving conditions. Overdrive provides four gear ratios plus a
converter clutch operation. Depress the accelerator in order to downshift for safe passing.
3 -- Drive position is used for city traffic, hilly terrain, and trailer towing. Drive provides three gear
ranges and prevents the transmission from operating in fourth gear. Depress the accelerator in
order to downshift.
2 -- Manual Second provides two gear ratios under most operating conditions. Manual Second
provides acceleration and engine braking. You may select this range at any vehicle speed, but
you cannot downshift the transmission into Second gear until the vehicle speed drops below
- approximately 100 km/h (62 mph).
1 -- Manual Lo provides maximum engine braking. You may select this range at any vehicle
speed, but you cannot downshift the transmission into First gear until the vehicle speed drops
below approximately 60 km/h (37 mph). |
Transmission Component and System Description
The mechanical components of this unit are as follows:
A torque converter with a torque converter clutch (TCC)
A drive link assembly
Intermediate/4th and Lo/Reverse friction band assemblies
Forward, Coast, 2nd, Reverse, and Direct multiple disc clutch assemblies
Two planetary gear sets: Input and Reaction
Two roller clutches - Lo and 2nd
One sprag clutch
One vane type oil pump
One control valve assembly
A final drive and differential assembly
The electrical components of this unit are as follows:
,
Two shift solenoid valves, 1-2 and 2-3
A torque converter clutch pulse width modulated (TCC PWM) solenoid valve
A transmission pressure control (PC) solenoid valve
An automatic transmission fluid temperature (TFT) sensor
Two speed sensors: input and output speed sensor
An automatic transmission fluid pressure (TFP) manual valve position switch assembiy
An automatic transmission wiring harness assembly
A park/neutral position switch
Page 67
2001 Chevrolet Cavalier Restoration Kit
Adapt Function
Transmission Adapt Function °
The 4T40-E transmission uses a line pressure control system, which has the ability to continuously adapt
the system's line pressure. This compensates for normal wear of the following parts:
e The clutch fiber plates
e The seals
e The springs
The PCM maintains the Upshift Adapt parameters for the transmission The PCM monitors the AT ISS
sensor and the AT OSS during commanded shifts in order to determine if a shift is occurring too fast or
too slow. The PCM adjusts the signal from the transmission pressure control solenoid in order to maintain
a set shift feel. | | |
Transmission adapts must be reset whenever the transmission is overhauled or replaced.
Clutch
Fastener Tightening Specifications
Clutch Actuator Bleed Screw 2 N-m 18 lb in
Clutch Cover to Flywheel Bolt 2.2L (Vin 4) 20 N-m dere rotate 30 15 1b ft plus rotate 30
Clutch Cover to Flywheel Bolts 2.4L (Vin T) 20 N-m rons 45 151b degrees 45
Clutch Master Cylinder and Clutch Pedal 24 N-m 15 Ib ft
Bracket Nut |
Hydraulic Clutch Description
Clutch Spin Down Time
‘Check the clutch spin down time as follows:
Apply the parking brake. Block the vehicle wheels.
Shift the manual transmission into neutral.
Start the engine. Run the engine at idle speed.
Engage the clutch.
Disengage the clutch. Wait 9 seconds.
Shift the transmission into reverse.
О о К о ю
Clutch Driving Members
The clutch driving members are two flat surfaces machined to a smooth finish. They are:
1. The rear face of the engine flywheel
2. The front face of the clutch pressure plate
Clutch Driven Members
The driven member is the clutch driven plate. The clutch driven plate has a splined hub. The splined hub
slides lengthwise along the splines of the input shaft. The splined hub drives the input shaft through these
same splines. The driving and driven members are held together with a spring pressure. This pressure is
exerted by a diaphragm spring in the clutch pressure plate.
Page 68
2001 Chevrolet Cavalier Restoration Kit
Hydraulic Clutch Fluid
Notice
Do not use mineral or paraffin-base oil in the clutch hydraulic system. These fluids may damage the
rubber parts in the cylinders.
When refilling the system or adding fluid after service, use GM Delco Supreme No. 2 Brake Fluid, or
equivalent that meets DOT 3 specifications.
Hydraulic Clutch Operating Members
The clutch system consists of the following components:
A master cylinder with a reservoir
A switch
An concentric slave cylinder connected to hydraulic tubing
Pressure Plate
Clutch Cover
Diaphragm Springs
Release Bearing
Clutch Disc
Torsional Springs
With the depression of the clutch pedal, the clutch master cylinder becomes pressurized from the force of
the push rod into the master cylinder. This forces hydraulic fluid into the tubing from the master cylinder to
the concentric slave cylinder. The concentric slave cylinder then engages by pushing the releasing
bearing into the diaphragm spring and release the clutch. A hole in the cowl panel accommodates the
master cylinder. A quick connect coupling helps route the hydraulic tubing. the concentric slave cylinder is
inside the transmission and on the input bearing retainer. The hydraulic control system can be replaced
without having to gain access to the clutch system internal components , simply engage the quick
connect coupling mounted through the transmission housing. No adjustments to the clutch system are
necessary. as the clutch wears, the fluid level in the master cylinder reservoir changes to compensates
for clear wear. A new system will have fluid in the reservoir. An electrical switch on the push rod has two
functions: One function is a clutch interlock, ensuring the engine does not start unless the clutch pedal is
engaged (positioned to the floor). The second function is to cut off the cruise-control system (if so
equipped) when the clutch pedal is engaged.
Page 69
2001 Chevrolet Cavalier Restoration Kit
Abbreviations and Meanings
Appendix A
Ampere(s)
A
ABS Antilock Brake System
A/C Air Conditioning
AC Alternating Current
ACC Accessory, Automatic Climate Control
~~ ACL Air Cleaner В
- ACR4 Air Conditioning Refrigerant, Recovery, Recycling, Recharging
AD Automatic Disconnect
A/D Analog to Digital
ADL Automatic Door Lock
— AF Air/Fuel Ratio
AH Active Handling
AIR Secondary Air Injection
ALC Automatic Level Control, Automatic Lamp Control
AM/FM - |JAmplitude Modulation/Frequency Modulation
Ant Antenna
AP Accelerator Pedal
APCM Accessory Power Control Module
API American Petroleum Institute
APP Accelerator Pedal Position
APT . ¡Adjustable Part Throttle
ASM Assembly, Accelerator and Servo Control Module
ASR Acceleration Slip Regulation
AT Automatic Transmission/Transaxle
ATC Automatic Transfer Case, Automatic Temperature Control
ATDC After Top Dead Center
ATSLC Automatic Transmission Shift Lock Control
Auto Automatic
avg Average
A4WD Automatic Four-Wheel Drive
AWG American Wire Gage
B+ Battery Positive Voltage
BARO Barometric Pressure
BATT Battery
BBV Brake Booster Vacuum
BCA Bias Control Assembly
BCM Body Control Module
Page i
2001 Chevrolet Cavalier Restoration Kit Appendix A
BHP Brake Horsepower
BLK Black
BLU Blue
BP Back Pressure
BPCM |Battery Pack Control Module
BPMV Brake Pressure Modulator Valve
BPP Brake Pedal Position
BRN Brown
BTDC Before Top Dead Center
BTM Battery Thermal Module
BTSI Brake Transmission Shift Interlock
Btu British Thermal Units
°C Degrees Celsius
- CAC Charge Air Cooler
CAFE - [Corporate Average Fuel Economy
Cal Calibration |
Сат Camshaft
CARB California Air Resources Board
CC Coast Clutch
cm? Cubic Centimeters
CCM Convenience Charge Module, Chassis Control Module
CCOT Cycling Clutch Orifice Tube
CCP Climate Control Panel
CD [Compact Disc
CE Commutator End
CEAB Cold Engine Air Bleed
CEMF Counter Electromotive Force
CEX Cabin Exchanger
cfm Cubic Feet per Minute
cg Center of Gravity
CID Cubic Inch Displacement
CKP Crankshaft Position
CKT Circuit |
C/Ltr Cigar Lighter
CL Closed Loop
CLS Coolant Level Switch
CMC Compressor Motor Controller
CMP Camshaft Position
CNG Compressed Natural Gas
CO Carbon Monoxide
CO2 Carbon Dioxide
Page ii
2001 Chevrolet Cavalier Restoration Kit Appendix A
Coax Coaxial
COMM Communication
Conn Connector
CPA Connector Position Assurance
CPP Clutch Pedal Position
CPS Central Power Supply
CPU Central Processing Unit
CRT Cathode Ray Tube
CRTC Cathode Ray Tube Controller
CS Charging System
CSF Central Sequential Fuel Injection
CTP Closed Throttle Position
cu ft Cubic Foot/Feet
cu in Cubic Inch/Inches
CV Constant Velocity Joint |
CVRSS Continuously Variable Road Sensing Suspension
Cyl |Cylinder(s)
DAB
—]——;—];;];.L—O—
Delayed Accessory Bus
dB Decibels
dBA Decibels on A-weighted Scale
DC Direct Current, Duty Cycle
DCM Door Control Module
DE Drive End
DEC Digital Electronic Controller
DERM Diagnostic Energy Reserve Module
Di Distributor Ignition
dia Diameter
DIC Driver Information Center
Diff | Differential
DIM Dash Integration Module
DK Dark
DLC Data Link Connector
DMCM Drive Motor Control Module
DMM Digital Multimeter
DMSDS Drive Motor Speed and Direction Sensor
DMU Drive Motor Unit — |
DOHC Dual Overhead Camshafts
DR, Drvr Driver
DRL Daytime Running Lamps
DTC Diagnostic Trouble Code
Page iii
2001 Chevrolet Cavalier Restoration Kit Appendix A
E
EBCM Electronic Brake Control Module
EBTCM Electronic Brake and Traction Control Module
EC Electrical Center, Engine Control
ECC Electronic Climate Control
ECI Extended Compressor at Idle
ECL Engine Coolant Level
ECM Engine Control Module, Electronic Control Module
ECS Emission Control System |
ECT Engine Coolant Temperature
EEPROM [Electrically Erasable Programmable Read Only Memory
EEVIR Evaporator Equalized Values in Receiver
EFE Early Fuel Evaporation
EGR Exhaust Gas Recirculation
EGR TVW Exhaust Gas Recirculation Thermal Vacuum Valve
EHPS Electro-Hydraulic Power Steering
El Electronic Ignition
ELAP Elapsed
ELC Electronic Level Control
E/M English/Metric
EMF Electromotive Force
EMI — |Electromagnetic Interference
Eng Engine
"EOP Engine Oil Pressure
EOT Engine Oil Temperature
EPA Environmental Protection Agency
EPR Exhaust Pressure Regulator
EPROM Erasable Programmable Read Only Memory
ESB Expansion Spring Brake
ESC Electronic Suspension Control
ESD Electrostatic Discharge
ESN Electronic Serial Number
ETC Electronic Throttle Control, Electronic Temperature Control, Electronic Timing
Control
ETCC [Electronic Touch Climate Control
ETR Electronically Tuned Receiver
ETS Enhanced Traction System
EVAP Evaporative Emission
EVO Electronic Variable Orifice
Exh Exhaust
Page iv
2001 Chevrolet Cavalier Restoration Kit
Appendix A
F
°F Degrees Fahrenheit
FC Fan Control
FDC Fuel Data Center
FED Federal All United States except California
FEDS Fuel Enable Data Stream
FEX Front Exchanger
FF Flexible Fuel
FFH ~ {Fuel-Fired Heater
FI Fuel Injection
FMVSS Federal U.S. Motor Vehicle Safety Standards
FP Fuel Pump |
ft Foot/Feet
FT Fuel Trim |
F4WD Full Time Four-Wheel Drive
4WAL Four-Wheel Antilock
4WD Four-Wheel Drive
FW Flat Wire |
FWD Front Wheel Drive, Forward
Grams, Gravitational Acceleration
g
GA Gage, Gauge
gal Gallon
gas Gasoline
GCW Gross Combination Weight
Gen Generator
GL Gear Lubricant
GM General Motors
GM SPO General Motors Service Parts Operations
gnd Ground:
gpm Gallons per Minute
GRN Green
GRY Gray
GVWR Gross Vehicle Weight Rating
H Hydrogen
H20 Water
Harn Harness
HC Hydrocarbons
H/CMPR
High Compression
Page v
2001 Chevrolet Cavalier Restoration Kit Appendix A
HD Heavy Duty
HDC Heavy Duty Cooling
hex Hexagon, Hexadecimal
Hg Mercury
Hi Alt High Altitude
HO2S Heated Oxygen Sensor
hp | Horsepower
HPL High Pressure Liquid
HPS High Performance System
HPV High Pressure Vapor
HPVS — |Heat Pump Ventilation System
Htd Heated
HTR Heater
HUD Head-up Display
HVAC [Heater-Ventilation-Air Conditioning
HVACM Heater-Vent-Air Conditioning Module
HVIL High Voltage Interlock Loop
HVM Heater Vent Module
Hz Hertz
IAC Idle Air Control
IAT Intake Air Temperature
IC Integrated Circuit, Ignition Control
ICCS Integrated Chassis Control System
ICM Ignition Control Module
ID Identification, Inside Diameter
IDI Integrated Direct Ignition
IGBT Insulated Gate Bi-Polar Transistor
ign Ignition
ILC Idle Load Compensator
in Inch/Inches
INJ Injection
inst Instantaneous, Instant
IP Instrument Panel
IPC Instrument Panel Cluster
IPM [Instrument Panel Module
PEC Instrument Panel Electrical Center
ISC Idie Speed Control
ISO International Standards Organization
ISS Input Speed Shaft, Input Shaft Speed
Page vi
2001 Chevrolet Cavalier Restoration Kit
Appendix A
Keep Alive Memory
KDD Keyboard Display Driver
— kg Kilogram
kHz Kilohertz
km Kilometer
km/h Kilometers per Hour
km/l Kilometers per Liter
kPa Kilopascals
KS Knock Sensor
kV Kilovolts
|Liter
Four Cylinder Engine, In-Line
L4
L6 Six-Cylinder Engine, In-Line
Ib Pound
Ib ft Pound Feet Torque
Ib in Pound Inch Torque
LCD Liquid Crystal Display
LDCL Left Door Closed Locking
LDCM Left Door Control Module
LDM Lamp Driver Module
LED Light Emitting Diode
LEV Low Emissions Vehicle
LF Left Front
Im Lumens
LR Left Rear
LT Left
LT Light
LT Long Term
LTPI Low Tire Pressure Indicator
Low Tire Pressure Warning System
MAF Mass Air Flow
Man Manual |
MAP Manifold Absolute Pressure
MAT Manifold Absolute Temperature
max Maximum
M/C Mixture Control
MDP Manifold Differential Pressure
Page vii
2001 Chevrolet Cavalier Restoration Kit
Appendix A
MFI Multiport Fuel Injection
mi Miles
MIL Malfunction Indicator Lamp
min Minimum
MIN Mobile Identification Number
mL. Milliliter
mm Millimeter
mpg Miles per Gallon
mph Miles per Hour
ms Millisecond ВЕ
MST ~ [Manifold Surface Temperature
MSVA Magnetic Steering Variable Assist, Magnasteer®
M/T Manual Transmission/Transaxle
MV Megavolt
mV Millivolt
NAES North American Export Sales
NC [Normally Closed
NEG [Negative
Neu Neutral
NI Neutral Idle
NiMH Nickel Metal Hydride
NLGI National Lubricating Grease Institute
N-m Newton-meter Torque
NO Normally Open
NOx Oxides of Nitrogen
NPTC National Pipe Thread Coarse
NPTF National Pipe Thread Fine
NOVRAM Non-Volatile Random Access Memory
Oxygen
O2S Oxygen Sensor
OBD On-Board Diagnostics
ОВО | On-Board Diagnostics Second Generation
OC Oxidation Converter Catalytic
OCS Opportunity Charge Station
OD Outside Diameter
ODM Output Drive Module
ODO [Odometer
OE Original Equipment
OEM Original Equipment Manufacturer
OHC Overhead Camshaft
Page viii
Appendix A
2001 Chevrolet Cavalier Restoration Kit
ohms Ohm
OL Open Loop, Out of Limits
ORC Oxidation Reduction Converter Catalytic
ORN Orange
ORVR On-Board Refueling Vapor Recovery
OSS Output Shaft Speed
oz Ounce(s) — |
в
РАС Polyalkylene Glycol
PAIR Pulsed Secondary Air Injection
PASS, PSGR [Passenger
PASS-Key® |Personalized Automotive Security System
P/B Power Brakes |
РС "Pressure Control
PCB Printed Circuit Board
‚РСМ Powertrain Control Module
PCS Pressure Control Solenoid
PCV Positive Crankcase Ventilation
PEB Power Electronics Bay
PID Parameter Identification
PIM Power Inverter Module
PM Permanent Magnet Generator
P/N Part Number
PNK Pink
PNP Park/Neutral Position
PRNDL Park, Reverse, Neutral, Drive, Low
POA Pilot Operated Absolute Valve
POS Positive, Position
POT Potentiometer Variable Resistor
PPL Purple
ppm Parts per Million
PROM Programmable Read Only Memory
P/S, PS Power Steering
PSCM Power Steering Control Module, Passenger Seat Control Module
PSD Power Sliding Door
PSP Power Steering Pressure
psi Pounds per Square Inch
psia Pounds per Square Inch Absolute
psig Pounds per Square Inch Gauge
pt Pint
PTC Positive Temperature Coefficient
PWM Pulse Width Modulated
Page ix
2001 Chevrolet Cavalier Restoration Kit | | Appendix A
| Q
QDM Quad Driver Module ©
at Quart(s)
R-12 Refrigerant-12
R-134a Refrigerant-134a
RAM Random Access Memory, Non-permanent memory device, memory contents are lost
when power is removed.
RAP Retained Accessory Power
RAV Remote Activation Verification
- RCDLR Remote Control Door Lock Receiver
RDCM Right Door Control Modul
Ref Reference
Rev |Reverse
REX |Rear Exchanger
RIM Rear Integration Module
RF Right Front, Radio Frequency
RFA Remote Function Actuation
RFI Radio Frequency Interference
RH Right Hand
RKE Remote Keyless Entry
Rly Relay
ROM Read Only Memory, Permanent memory device, memory contents are retained when
power is removed.
RPM [Revolutions per Minute Engine Speed
RPO Regular Production Option
RR Right Rear |
RSS Road Sensing Suspension
RTD Real Time Damping
RT Right
RTV Room Temperature Vulcanizing Sealer
RWAL Rear Wheel Antilock
RWD Rear Wheel Drive
S Second(s)
SAE Society of Automotive Engineers
SC Supercharger
SCB Supercharger Bypass
SCM Seat Control Module
SDM Sensing and Diagnostic Module
SEO Special Equipment Option
SFI Sequential Multiport Fuel Injection
Page x
ini A
2001 Chevrolet Cavalier Restoration Kit
Appendix A
Si System International Modern Version of Metric System
SIAB Side Impact Air Bag
SIR Supplemental Inflatable Restraint
SLA Short/Long Arm Suspension
sol Solenoid |
502 Sulfur Dioxide
SP Splice Pack
S/P Series/Parallel
SPO Service Parts Operations
SPS Service Programming System, Speed Signal
sqft, ft2 |Square Foot/Feet |
sq in, in? Square Inch/Inches
SRC Service Ride Control |
SRI Service Reminder Indicator
SRS ~ |Supplemental Restraint System
SS Shift Solenoid
ST Scan Tool
STID Station Identification Station ID
S4WD Selectable Four-Wheel Drive
Sw Switch
SWPS Steering Wheel Position Sensor
syn
Synchronizer
TAC
Throttle Actuator Control
Tach Tachometer
TAP Transmission Adaptive Pressure, Throttle Adaptive Pressure
TBI Throttle Body Fuel Injection
TC Turbocharger, Transmission Control
TCC Torque Converter Clutch
TCS Traction Control System
TDC Top Dead Center
TEMP Temperature
Term Terminal
TFP Transmission Fluid Pressure
TFT Transmission Fluid Temperature
THM Turbo Hydro-Matic
TIM Tire Inflation Monitoring, Tire Inflation Module
TOC | Transmission Oil Cooler
TP Throttle Position
TPA Terminal Positive Assurance
TPM Tire Pressure Monitoring, Tire Pressure Monitor
TR Transmission Range
Page xi
2001 Chevrolet Cavalier Restoration Kit on Appendix A
TRANS Transmission/Transaxle
TT Tell Tail Warning Lamp
TV Throttle Valve
TVRS Television and Radio Suppression
TVV Thermal Vacuum Valve
TWC Three Way Converter Catalytic
TWC+OC Three Way + Oxidation Converter Catalytic
TXV Thermal Expansion Valve
UART + ¡Universal Asynchronous Receiver Transmitter
U/H - |Underhood
U/HEC Underhood Electrical Center
U-joint Universal Joint
UTD Universal Theft Deterrent
uv Ultraviolet
Volt(s), Voltage
Six-Cylinder Engine, V-Type
Eight-Cylinder Engine, V-Type
Vac Vacuum
VAC Vehicle Access Code
VATS Vehicle Anti-Theft System
VCIM Vehicle Communication Interface Mode
VCM Vehicle Control Module
V dif |Voltage Difference
VDOT Variable Displacement Orifice Tube
VDV Vacuum Delay Valve
vel Velocity
VES © Variable Effort Steering
VF Vacuum Fluorescent
VIO Violet
VIN |Vehicle Identification Number
VLR Voltage Loop Reserve
VMV Vacuum Modulator Valve
VR Voltage Regulator
V ref Voltage Reference
VSES Vehicle Stability Enhancement System
VSS Vehicle Speed Sensor
Page xii
2001 Chevrolet Cavalier Restoration Kit
w/
W/B
WHL
WHT
w/o
WOT
W/P
W/S
WSS
WU-OC
WU-TWC
X-valve
yd
Wheel Base
Open Throttle
ater Pump
Speed Sensor |
arm Up Oxidation Converter Catalytic
arm Up Three-Way Converter Catalytic
(Expansion Valve
ard(s)
ellow
Appendix A
Page xiii
2001 Chevrolet Cavalier Restoration Kit Appendix C
Conversion - English/Metric
In order to calculate English measurement, divide by the number in the center column.
In order to calculate metric measurement, multiply by the number in the center column.
E — | Length ~~ a
in 25.4 mm
0.3048
0.9144
m
16,387.00
16.387
0.0164
0.9464
3.7854
0.764
0.4536
— 907.18
0.907 tonne (t)
kg
9.807 |
0.278 newtons (N)
4.448
0.3048
0.0254
0.11298
1.3558
0.745
Page |
2001 Chevrolet Cavalier Restoration Kit
inches of H20
Ib/sq in
Btu
Ib ft
| kW hour
Foot Candle
mph
(°F - 32) 5/9
°F
235.215/mpg
Pressure (Stress)
0.2488
6.895
1055
1.3558
3,600,000.00
1.6093
10.764 -
Appendix C
J (J= one Ws)
Im/m?
km/h
°C
(9/5 °C + 32)
100 km/L
- Pace ii
Fea
2001 Chevrolet Cavalier Restoration Kit Appendix C
Equivalents - Decimal and Metric
0.015625 0.39688
1/32 0.03125 0.79375
3/64 0.046875 1.19062
1/16 0.0625 1.5875
5/64 0.078125 1.98437
3/32 0.09375 2.38125
7/64 0.109375 2.77812
1/8 0.125 3.175
9/64 0.140625 3.57187
5/32 0.15625 3.96875
11/64 0.171875 4.36562
3/16 0.1875 4.7625
13/64 0.203125 5.15937
7/32 0.21875 5.55625
15/64 0.234375 5.95312
1/4 0.25 6.35
17/64 0.265625 6.74687
0/32 0.28125 7.14375
19/64 0.296875 7.54062
5/16 0.3125 7.9375
21/64 0.328125 8.33437
11/32 0.34375 8.73125
23/64 0.359375 0.12812
3/8 0.375 9.525
25/64 0.390625 0.92187
13/32 0.40625 10.31875
27/64 0.421875 10.71562
7/16 — 0.4375 11.1125
29/64 0.453125 11.50937
15/32 0.46875 11.90625
31/64 0.484375 12.30312
1/2 0.5 12.7
33/64 0.515625 13.09687
17/32 0.53125 13.49375
35/64 0.546875 13.89062
9/16 0.5625 14.2875
37/64 0.578125 14.68437
19/32 0.59375 15.08125
39/64 0.609375 15.47812
Page iii
2001 Chevrolet Cavalier Restoration Kit
Appendix C
5/8 0.625 15.875
41/64 0.640625 16.27187
21/32 0.65625 16.66875
43/64 0.671875 17.06562
11/16 0.6875 17.4625
45/64 0.703125 17.85937
23/32 0.71875 18.25625
47/64 0.734375 —18.65312
3/4 0.75 19.05
49/64 0.765625 19.44687
25/32 0.78125 19.84375
51/64 0.796875 20.24062
13/16 0.8125 20.6375
53/64 0.828125 21.03437
27/32 0.84375 21.43125
55/64 0.859375 21.82812
7/8 0.875 22.225
57/64 0.890625 22.62187
29/32 0.90625 23.01875
59/64 0.921875 23.41562
15/16 0.9375 23.8125
61/64 0.953125 24.20937
31/32 0.96875 24.60625
63/64 0.984375 25.00312
1 1.0 25.4
Page iv
2001 Chevrolet Cavalier Restoration Kit - “ Appendix D
Fasteners
Metric Fasteners
This vehicle provides fastener dimensions using the metric system. Most metric fasteners are
approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same
nominal diameter, thread pitch, and strength.
A number marking identifies the OE metric fasteners except cross-recess head screws. The number also
indicates the strength of the fastener material. A Posidrive® or Type 1A cross-recess identifies a metric
cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in
Posidrive® recess head screws.
GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined
standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while
retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with
nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The
thread pitch is midway between the English coarse and fine thread pitches. |
Fastener Strength Identification
English Bolt, Grade 2 (Strength Class)
English Bolt, Grade 5 (Strength Class)
English Bolt, Grade 7 (Strength Class)
English Bolt, Grade 8 (Strength Class)
Metric Nut, Strength Class 9
Metric Bolts, Strength Class Increases as Numbers Increase
DONNA
The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class
identification is embossed on the head of each bolt. The English, inch strength classes range from grade
2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class.
The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8
bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength
identification number on the nut face.
Page i
2001 Chevrolet Cavalier Restoration Kit | | Appendix D
The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket
parts channels are designed to metric standards of countries other than the United States, and may
exhibit the following: |
e Lower strength
e No numbered head marking system
e Wrong thread pitch
The metric fasteners on GM products are designed to new, international standards. The following are the
common sizes and pitches, except for special applications:
M6.0 X 1
M8 X 1.25
M10 X 1.5
M12 X 1.75
M14 X 2.00
M16 X 2.00
| Prevailing Torque Fasteners
Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in
order to prevent the fastener from loosening.
All Metal Prevailing Torque Fasteners
These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener.
Nylon Interface Prevailing Torque Fasteners
These fasteners accomplish the thread interface by the presence of a nylon material on the fastener
threads.
Adhesive Coated Fasteners
These fasteners accomplish the thread interface by the presence of a thread- -locking compound on the
fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be
reused and the applicable thread-locking compound to apply to the fastener.
© Y © © ®
1 2 3 4 5
585 8
1. Prevailing Torque Nut, Center Lock Type
2. Prevailing Torque Nut, Top Lock Type
Page ii
2001 Chevrolet Cavalier Restoration Kit Appendix D
3. Prevailing Torque Nut, Nylon Patch Type
4. Prevailing Torque Nut, Nylon Washer Insert Type
5. Prevailing Torque Nut, Nylon Insert Type
6. Prevailing Torque Bolt, Dry Adhesive Coating Type
7. Prevailing Torque Bolt, Thread Profile Deformed Type
8. Prevailing Torque Bolt, Nylon Strip Type
9. Prevailing Torque Bolt, Out-of-Round Thread Area Type
A
prevailing torque fastener may be reused ONLY if;
e The fastener and the fastener counterpart are clean and not damaged
e There is no rust on the fastener |
e The fastener develops the specified minimum torque against its counterpart prior to the fastener
seating
Metric Prevailing Torque Fastener Minimum Torque Development |
| Metal Prevailing Torque Fasteners
6 mm 0.4 N-m 4 lb in
8 mm 0.8 N-m 7 Ibin
10 mm 1.4N-m 12 lb in
12 mm 2.1 N-m 19 lb in
14 mm 3 N'm 27 lb in
16 mm | 4.2 N-m | 37 lb in
20 mm 7 N-m 62 lb in
24 mm | 10.5 N-m 93 lb in
on Interface Prevailing Torque Fasteners
6 mm | | 0.3 N-m 3lbin
8 mM 0.6 N-m 5 Ib in
10 mm 1.1 N-m 10 lb in
12 mm | | 1.5 N-m | 13 Ib in
14 mm | 2.3N-m 20 Ib in
16 mm 3.4 N-m 30 Ib in
20 mm | 5.5 N-m | 49 Ib in
24 mm | 8.5 N-M 75 Ib in
Page iii
2001 Chevrolet Cavalier Restoration Kit Appendix D
English Prevailing Torque Fastener Minimum Torque Development
All Metal Prevailing Torque Fasteners
1/4 in | 0.5 N-m 4.5 lb in
5/16 in | | 0.8 Nm | 7.5 Ibin
3/8 in 1.3N-m 11.5 Ib in
7/16 in | 1.8 N-m 16 lb in
1/2 in 5 2.3 N-m 20 Ib in
9/16 in 3.2 N-m 28 Ib in
5/8 in 4 N-m | 36 Ib in
3/4 in | | 7 N-m ‚54 Ib in
Nylon Interface Prevailing Torque Fasteners
1/4 in | 0.3 N-m 3 Ib in
5/16 in 0.6 N-m 5 Ib in
3/8 in 1 N-m 9 lb in
7/16 in 1.3 N-m 12 lb in
1/2 in 1.8 N-m 16 Ib in
16 in 2.5 N-m 22 lb in
in 3.4 N-m 30 lb in
4 in 5 N-m | . 45 lb in
| Page iv
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement