Cavalier Manual

2003 Chevrolet Cavalier L4-2.2L VIN F Copyright © 2012, ALLDATA 10.
52SS Page 1
Chevrolet Cavalier L4-2.2L VIN F 1
Vehicle: Specifications
Automatic Transmission/Transaxle
Specifications
Transmission Fluid Temperature (TFP) Sensor Specifications
Transmission Fluid Pressure (TFP) Manual Valve Position Switch Logic
Transmission Range Switch Logic
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2003 Chevrolet Cavalier L4-2.2L VIN F Copyright © 2012, ALLDATA 10.52SS Page 2
Component Resistance
Battery Usage
Parasitic Draw
Generator Rated Output ........................................................................................................................................................................................ 105 A
Load Test Output ..................................................................................................................................................................................................... 73 A
System Specifications
Generator Usage
Voltage and Amperage

Temperature Vs Resistance Part 1
Temperature Vs Resistance Part 2
Fastener Tightening Specifications
Trim Height
Wheel Alignment
Part 1 Of 2
Part 2 Of 2
Part 1 Of 2
Part 2 Of 2
Part 1 Of 2
Part 2 Of 2

P/N 24200093 - Sensor, Input Speed - M6 x 1.0 x 15.0 (Qty 1) ........................................................................................................ 12 Nm (106 lb in)
P/N 24200093 - Clip, Wiring Harness - M6 x 1.0 x 15.0 (Qty 1) ...................................................................................................... 12 Nm (106 lb in)
P/N 24200209 - Channel Plate to Case - M6 x 1.0 x 63.0 (Qty 2) ..................................................................................................... 12 Nm (106 lb in)
P/N 24200207 - Channel Plate to Case - M6 x 1.0 x 28.0 (Qty 6) ..................................................................................................... 12 Nm (106 lb in)
P/N 24200207 - Channel Plate to Driven Sprocket Support M6 x 1.0 x 28.0 (Qty 1) ....................................................................... 14 Nm (124 lb in)
P/N 24200092 - Spring and Roller Assembly, Detent to Channel Plate - M6 x 1.0 x 19.0 (Qty 1) ................................................... 12 Nm (106 lb in)
P/N 24200214 - Spacer, Channel Plate to Driven Sprocket Support M6 x 1.0 x 70.0 (Qty 2) ............................................................ 14 Nm 124 lb in)
P/N 24200208 - Valve Body, Channel Plate to Case M6 x 1.0 x 103.0 (Qty 2) ................................................................................ 12 Nm (106 lb in)
P/N 24200205 - Valve Body, Channel Plate to Case M6 x 1.0 x 90.0 (Qty 5) .................................................................................. 12 Nm (106 lb in)
P/N 24200208 - Pump, Valve Body, Channel Plate to Case M6 x 1.0 x 103.0 (Qty 1) ..................................................................... 12 Nm (106 lb in)
P/N 24200205 - TFP Switch, Valve Body, Channel Plate to Case M6 x 1.0 x 90.0 (Qty 2) ............................................................. 12 Nm (106 lb in)
P/N 24200206 - TFP Switch, Valve Body, Channel Plate M6 x 1.0 x 51.0 (Qty 3) .......................................................................... 12 Nm (106 lb in)
P/N 24200209 - TFP Switch, Valve Body, Channel Plate M6 x 1.0 x 63.0 (Qty 1) .......................................................................... 12 Nm (106 lb in)
P/N 24200206 - Valve Body to Channel Plate M6 x 1.0 x 51.0 (Qty 5) ............................................................................................ 12 Nm (106 lb in)
P/N 24200209 - Pump, Valve Body to Channel Plate M6 x 1.0 x 63.0 (Qty 1) ................................................................................. 12 Nm (106 lb in)
P/N 24200205 - Pump, Valve Body to Channel Plate M6 x 1.0 x 90.0 (Qty 6) ................................................................................. 12 Nm (106 lb in)
P/N 24200207 - Cover Assembly, Intermediate 4th Servo to Case M6 x 1.0 x 28.0 (Qty 3) ............................................................ 12 Nm (106 lb in)
P/N 24200207 - Cover, Lo/Reverse Servo to Case M6 x 1.0 x 28.0 (Qty 3) ..................................................................................... 12 Nm (106 lb in)
P/N 24200092 - Tube Assembly, Transmission Oil to Case M6 x 1.0 x 19.0 (Qty 2) ....................................................................... 12 Nm (106 lb in)
P/N 24200092 - Tube Assembly, Transmission Oil to Lo/Reverse Servo Cover - M6 x 1.0 x 19.0 (Qty 1) ..................................... 12 Nm (106 lb in)
P/N 24200092 - Tube Assembly, Transmission Oil to Forward Clutch Support - M6 x 1.0 x 19.0 (Qty 1) .................................... 12 Nm ( 106 lb in)
P/N 24200091 - Sensor, Output Speed (Stud)M6 x 1.0 x 15.0 (Qty 1) .............................................................................................. 12 Nm (106 lb in)
P/N 24203911 - Bottom Pan to Case - M6 x 1.0 x 19.0 (Qty 12) ...................................................................................................... 12 Nm (106 lb in)
P/N 24208309 - Cover, Side to Case (Stud) M8 x 1.25 x 28.0 (Qty 1) ................................................................................................ 20 Nm (15 lb ft)
P/N 24203912 - Cover, Side to Case - M8 x 1.25 x 28.0 (Qty 10) ....................................................................................................... 20 Nm (15 lb ft)
P/N 8685658 - Support Assembly, Drive Sprocket to Case M6 x 1.0 x 17.2 (Qty 6) ........................................................................ 12 Nm (106 lb in)
P/N 8654382 - Plug, Pipe - 1/8-27 NPTF (Qty 2) .............................................................................................................................. 12 Nm (106 lb in)
Reverse Clutch Backing Plate Specifications

8.970-9.433 mm (0.353-0.371 inch) ............................................................................................................................................................................ A
9.434-10.007 mm (0.372-0.393 inch) ........................................................................................................................................................................... B
10.008-10.470 mm (0.394-0.412 inch) ......................................................................................................................................................................... C
Fluid Pan, A/T

Oil Pan to Case ................................................................................................................................................................................... 10 N-m (89 in.lb)
Frame and Underbody

Body Front End

Body Rear End

Bumper
Doors
Exterior Moulding / Trim

Console
Dashboard / Instrument Panel

Seats
Brake Rotor/Disc
Minimum thickness of friction material ....................................................................................................................................... 0.76 mm (0.030 inch)
Brake Rotor/Disc
DISC BRAKE COMPONENT SPECIFICATIONS
Brake Rotor Diameter .................................................................................................................................................................. 10.197 in (259.0 mm)
Brake Rotor Discard Thickness* .................................................................................................................................................... 0.736 in (18.70 mm)
Brake Rotor Maximum Allowable Assembled Lateral Runout ........................................................................................................ 0.002 in (0.06 mm)
Brake Rotor Maximum Allowable Scoring ...................................................................................................................................... 0.059 in (1.50 mm)
Brake Rotor Maximum Allowable Thickness Variation ................................................................................................................ 0.001 in (0.025 mm)
Brake Rotor Minimum Allowable Thickness after Refinish ........................................................................................................ 0.739 in (18.776 mm)
Brake Rotor Thickness - New** ................................................................................................................ 0.806 in - 0.796 in (20.48 mm - 20.22 mm)
* All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing the rotor,
replace any rotor that does not meet the minimum thickness specification.
** New rotors could range to 0.786 in (19.96 mm) due to thickness tolerances.
Drum Brake Component Specifications
Park Brake Warning Lamp Switch Mounting Screw 26 ft. lbs.
Parking Brake Cable Guide Mounting Nuts 81 inch lbs.
Parking Brake Level Mounting Nuts 18 ft. lbs.
Pressure Plate
clutch cover to flywheel bolts ............................................................................................................................................................ 24 Nm (18 ft. lbs.)
Fastener Tightening Specifications Part 1
Fastener Tightening Specifications Part 2
ENGINE COOLING / Fastener Tightening Specifications
Engine - Coolant Temperature Sensor/Switch

Engine Coolant Temperature Sensor ................................................................................................................................................. 22 Nm (16 ft. lbs.)
Radiator
Upper Radiator Mount Bolt ........................................................................................................................................................... 10 Nm (89 inch lbs.)
Radiator Cooling Fan Motor

Cooling Fan Bolt .............................................................................................................................................................................. 6 Nm (53 inch lbs.)
Thermostat Housing, Engine Cooling

Thermostat Housing to Block Bolts ............................................................................................................................................... 10 Nm (89 inch lbs.)
Water Pump
Water Pump Access Cover Bolts ..................................................................................................................................................... 7 Nm (62 inch lbs.)
Water Pump Bolts .............................................................................................................................................................................. 25 Nm (18 ft. lbs.)
Water Pump Sprocket Bolts ........................................................................................................................................................... 10 Nm (89 inch lbs.)
General Engine Specifications

General
Overhaul
Engine Mechanical Specifications
General
Overhaul
Tightening Sequence
Cylinder Head
Refer to the procedure See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Service and Repair
Camshaft Bearing Caps

Refer to the procedure See: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Camshaft/Service and Repair
Exhaust Manifold
Thread Repair Specifications
Engine Block-Front View
Engine Block-Back View
Engine Block-Left Side View
Engine Block-Bottom View
Engine Block-Right Side View
Engine Block-Top View
Lower Crankcase - Front View
Lower Crankcase-Back View
Lower Crankcase - Bottom View
Lower Crankcase - Left View
Lower Crankcase-Right View
Cylinder Head-Top View
Cylinder Head-Intake Manifold Deck View
Cylinder Head-Exhaust Manifold Deck View
Cylinder Head-Front View
Cylinder Head-Back View

Note: 1, 2, 5, 6 holes are oil passages.
Cylinder Head-Bottom View
Metric-English Conversion Factors

CONVERSION FACTORS
Camshaft Bearing
For Camshaft Bearing cap Tightening Sequence: Refer to the procedure See: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/
Camshaft Bearing Cap Bolt ............................................................................................................................................................ 10 Nm (89 inch lbs.)

Intake Camshaft Rear Cap Bolt ......................................................................................................................................................... 25 Nm (18 ft. lbs.)
Cam Bearing I.D. ........................................................................................................................................... 27.000-27.021 mm (1.0630-1.0638 inch)
Camshaft Bearing Clearance .............................................................................................................................. 0.040-0.086 mm (0.0016-0.0034 inch)
Camshaft Gear/Sprocket
Camshaft Sprocket Bolt
First Pass ........................................................................................................................................................................................ 85 Nm (63 ft. lbs.)
Final Pass ................................................................................................................................................................................................... 30 degrees
Camshaft, Engine
Camshaft Bearing Cap Bolt ............................................................................................................................................................ 10 Nm (89 inch lbs.)
Intake Camshaft Rear Cap Bolt ......................................................................................................................................................... 25 Nm (18 ft. lbs.)
Cam Bearing I.D. ........................................................................................................................................... 27.000-27.021 mm (1.0630-1.0638 inch)
Cam Journal O.D. .......................................................................................................................................... 26.935-26.960 mm (1.0604-1.0614 inch)
Camshaft Bearing Clearance .............................................................................................................................. 0.040-0.086 mm (0.0016-0.0034 inch)
Camshaft Thrust Width-Cylinder Head ......................................................................................................... 20.868-20.920 mm (0.8215-0.8236 inch)
Camshaft Thrust Width-Camshaft ................................................................................................................. 21.000-21.052 mm (0.8268-0.8252 inch)
Camshaft Endplay .............................................................................................................................................. 0.040-0.144 mm (0.0016-0.0057 inch)
Cam Timing, Intake .............................................................................................................................................................................. 114-120° ATDC
Cam Timing, Exhaust ..................................................................................................................................................................... 111.5-117.5° BTDC
General
Overhaul
General
Overhaul
Tightening Sequence
Cylinder Head

Exhaust Manifold

Balance Shaft
Balance Shaft Bearing Carrier Bore in Block I.D. ............................................................................................. 42.000-42.016 mm (1.6535-1.6542 in)
Balance Shaft Bearing Carrier O.D. .................................................................................................................. 41.975-41.995 mm (1.6526-1.6534 in)
Balance Shaft Housing to Block Clearance ........................................................................................................... 0.005-0.041 mm (0.0002-0.0016 in)
Balance Shaft Bearing I.D. #1 ........................................................................................................................... 20.050-20.063 mm (0.7894-0.7899 in)
Balance Shaft Bearing I.D. #2 ........................................................................................................................... 36.776-36.825 mm (1.4479-1.4498 in)
Balance Shaft Journal O.D. #1 .......................................................................................................................... 20.000-20.020 mm (0.7874-0.7882 in)
Balance Shaft Journal O.D. #2 .......................................................................................................................... 36.723-36.743 mm (1.4458-1.4466 in)
Balance Shaft Bearing Clearance #1 ...................................................................................................................... 0.030-0.063 mm (0.0012-0.0025 in)
Balance Shaft Bearing Clearance #2 ...................................................................................................................... 0.033-0.102 mm (0.0013-0.0040 in)
Balance Shaft End Play ......................................................................................................................................... 0.100-0.300 mm (0.0020-0.0118 in)
Balance Shaft Chain Length ...................................................................................................................... 368.622-369.032 mm (14.5127-14.5288 in)
Balance of Shafts ............................................................................................................................................................. 4.05 Kg/mm per shaft, +/-6 %
Balance Shaft Bearing

Balance Shaft Bearing Carrier to Block Bolt ................................................................................................................................. 10 Nm (89 inch lbs.)
Balance Shaft Bearing Carrier Bore in Block I.D. ......................................................................................... 42.000-42.016 mm (1.6535-1.6542 inch)
Balance Shaft Bearing Carrier O.D. ............................................................................................................... 41.975-41.995 mm (1.6526-1.6534 inch)
Balance Shaft Bearing I.D. #1 ....................................................................................................................... 20.050-20.063 mm (0.7894-0.7899 inch)
Balance Shaft Bearing I.D. #2 ....................................................................................................................... 36.776-36.825 mm (1.4479-1.4498 inch)
Balance Shaft Bearing Clearance #1 ................................................................................................................... 0.030-0.063 mm (0.0012-0.0025 inch)
Balance Shaft Bearing Clearance #2 ................................................................................................................... 0.033-0.102 mm (0.0013-0.0040 inch)
Balance Shaft Chain Guide

Balance Shaft Adjustable Chain Guide Bolt .................................................................................................................................. 10 Nm (89 inch lbs.)
Balance Shaft Fixed Chain Guide Bolt .......................................................................................................................................... 10 Nm (89 inch lbs.)
Balance Shaft Gear
Balance Shaft Sprocket Bolt .............................................................................................................................................................. 50 Nm (37 ft. lbs.)
Connecting Rod Bearing

Rod Bearing Bore I.D. ................................................................................................................................... 52.118-52.134 mm (2.0519-2.0525 inch)
Rod Bearing Shell Thickness ............................................................................................................................... 1.539-1.545 mm (0.0606-0.608 inch)
Rod Bearing I.D., 90 degree .......................................................................................................................... 49.043-49.073 mm (1.9308-1.9320 inch)
Rod Bearing I.D., 45 degree ......................................................................................................................... With-in +0.009/-0.004 of 90 degree spec.
Rod Bearing to Crankpin Clearance .................................................................................................................. 0.029-0.069 mm (0.0011-0.0027 inch)
Rod Small End I.D. ........................................................................................................................................................................... 20.007-20.021 mm
Rod Side Clearance ............................................................................................................................................ 0.070-0.370 mm (0.0028-0.0146 inch)
Rod Twist ...................................................................................................................................................................................................... 0.040 max.
Rod Bend ....................................................................................................................................................................................................... 0.021 max.
Rod Large End Micro .................................................................................................................................................................................. 2.0 Ra max.
Rod Small End Micro .................................................................................................................................................................................. 0.3 Ra max.
Piston Pin Endplay ................................................................................................................................................ 0.19-1.16 mm (0.007 5-0.0461 inch)
Connecting Rod Bolt
First Pass ....................................................................................................................................................................................................... 18 ft.lbs.
Final Pass ............................................................................................................................................................................................................. 100°
Connecting Rod, Engine

Rod Bearing Bore I.D. ................................................................................................................................... 52.118-52.134 mm (2.0519-2.0525 inch)
Rod Bearing Shell Thickness ............................................................................................................................... 1.539-1.545 mm (0.0606-0.608 inch)
Rod Bearing I.D., 90 degree .......................................................................................................................... 49.043-49.073 mm (1.9308-1.9320 inch)
Rod Bearing I.D., 45 degree ......................................................................................................................... With-in +0.009/-0.004 of 90 degree spec.
Rod Bearing to Crankpin Clearance .................................................................................................................. 0.029-0.069 mm (0.0011-0.0027 inch)
Rod Small End I.D. ........................................................................................................................................................................... 20.007-20.021 mm
Rod Side Clearance ............................................................................................................................................ 0.070-0.370 mm (0.0028-0.0146 inch)
Rod Twist ...................................................................................................................................................................................................... 0.040 max.
Rod Bend ....................................................................................................................................................................................................... 0.021 max.
Rod Large End Micro .................................................................................................................................................................................. 2.0 Ra max.
Rod Small End Micro .................................................................................................................................................................................. 0.3 Ra max.
Piston Pin Endplay ................................................................................................................................................ 0.19-1.16 mm (0.007 5-0.0461 inch)
Connecting Rod Bolt
First Pass ....................................................................................................................................................................................................... 18 ft.lbs.
Final Pass ............................................................................................................................................................................................................. 100°
Crankshaft Main Bearing
Crankshaft Bearing Bolt Tightening Sequence
Install the NEW crankshaft bearing bolts in sequence finger tight.

- Tighten the crankshaft bearing bolts in sequence.
- Tighten the crankshaft bearing bolts to 20 Nm (15 ft. lbs.).
- Tighten the crankshaft bearing bolts 70 degrees using the torque angle meter.
Lower Crankcase Perimeter Tightening Sequence
-Tighten the lower crankcase to block peripheral bolts to 25 N-m (18 ft.lbs.)
Main Journal O.D. ......................................................................................................................................... 55.994-56.008 mm (2.2045-2.2050 inch)

Main Bearing Clearance .................................................................................................................................... 0.031-0.067 mm (0.0012-0.0026 inch)
Rod Pin O.D. .................................................................................................................................................. 49.000-49 014 mm (1.9291-1.9297 inch)
Rear Crankshaft Seal O.D. ..................................................................................................................................... 89.78-90.00 mm (3.535-3.543 inch)
Crankshaft Endplay ............................................................................................................................................ 0.050-0.380 mm (0.0012-0.0150 inch)
Balance of Crankshaft ............................................................................................................................................................................... 10 g/cm max.
Balance of Flywheel .................................................................................................................................................................................. 10 g/cm max.
Balance of Crankshaft Damper ........................................................................................................................................................... 0.09 kg/mm max.
Main Bearing Shell Thickness ........................................................................................................................... 4.030-4.037 mm (0.1587-0.1589 inch)
Main Bearing I.D. .......................................................................................................................................... 56.035-56.065 mm (2.2061-2.2073 inch)
Crankshaft Bearing - Lower Crankcase to Block
First Pass ....................................................................................................................................................................................................... 15 ft.lbs.
Final Pass ............................................................................................................................................................................................................... 70°
Crankshaft, Engine
Crankshaft Bearing Bolt Tightening Sequence
Install the NEW crankshaft bearing bolts in sequence finger tight.

- Tighten the crankshaft bearing bolts to 20 Nm (15 ft. lbs.).
- Tighten the crankshaft bearing bolts 70 degrees using the torque angle meter.
Lower Crankcase Perimeter Tightening Sequence
-Tighten the lower crankcase to block peripheral bolts to 25 N-m (18 ft.lbs.)
Main Journal O.D. ......................................................................................................................................... 55.994-56.008 mm (2.2045-2.2050 inch)

Main Bearing Clearance .................................................................................................................................... 0.031-0.067 mm (0.0012-0.0026 inch)
Rod Pin O.D. .................................................................................................................................................. 49.000-49 014 mm (1.9291-1.9297 inch)
Rear Crankshaft Seal O.D. ..................................................................................................................................... 89.78-90.00 mm (3.535-3.543 inch)
Crankshaft Endplay ............................................................................................................................................ 0.050-0.380 mm (0.0012-0.0150 inch)
Balance of Crankshaft ............................................................................................................................................................................... 10 g/cm max.
Balance of Flywheel .................................................................................................................................................................................. 10 g/cm max.
Balance of Crankshaft Damper ........................................................................................................................................................... 0.09 kg/mm max.
Main Bearing Shell Thickness ........................................................................................................................... 4.030-4.037 mm (0.1587-0.1589 inch)
Main Bearing I.D. .......................................................................................................................................... 56.035-56.065 mm (2.2061-2.2073 inch)
Crankshaft Bearing - Lower Crankcase to Block
First Pass ....................................................................................................................................................................................................... 15 ft.lbs.
Final Pass ............................................................................................................................................................................................................... 70°
Harmonic Balancer - Crankshaft Pulley

Crankshaft Pulley Bolt
First Pass ...................................................................................................................................................................................... 100 Nm (74 ft. lbs.)
Piston Pin, Engine

Piston Pin O.D. .............................................................................................................................................. 19.995-20.000 mm (0.7872-0.7874 inch)
Piston to Pin Clearance ...................................................................................................................................... 0.002-0.012 mm (0.0001-0.0005 inch)
Pin to Rod Clearance .................................................................................................................................................................... 0.007-0.026 mm
Piston Ring, Engine

Piston Diameter @ 14.5 mm up ................................................................................................................... 85.967-85.982 mm (13.3845-3.3851 inch)
Piston to Bore Clearance .................................................................................................................................... 0.010-0.041 mm (0.0004-0.0016 inch)
Piston Weight ..................................................................................................................................................................................................................
Piston Height .......................................................................................................................................................................... Max. 0.9 mm-below deck
Piston Pin Bore I.D. ....................................................................................................................................... 20.002-20.007 mm (0.7875-0.7877 inch)
Ring Groove Width, Top ....................................................................................................................................... 1.23-1.25 mm (0.0484-0.0492 inch)
Ring Groove Width, Second .................................................................................................................................. 1.52-1.54 mm (0.0598-0.0606 inch)
Ring Groove Width, Oil Control ........................................................................................................................... 2.52-2.54 mm (0.0992-0.1000 inch)
Piston Ring Thickness, Top ............................................................................................................................ 1.170-1.190 mm (0.0461-0.0469 inch)
Piston Ring Thickness, Second .......................................................................................................................... 1.471-1.490 mm (0.0579-0.0587 inch)
Piston Ring Thickness, Oil Control Rail ................................................................................................................... 0.43 mm max. (0.0169 in max.)
Piston Ring Thickness, Oil Control Spacer ....................................................................................................... 1.574-1.651 mm (0.0620-0.0650 inch)
Ring to Groove Clearance, Top ............................................................................................................................. 0.04-0.08 mm (0.0015-0.0031 inch)
Ring to Groove Clearance, Second .................................................................................................................... 0.030-0.069 mm (0.0012-0.0027 inch)
Ring to Groove Clearance, Oil Control ............................................................................................................. 0.090-0.106 mm (0.0035-0.0042 inch)
Ring Gap, Top ............................................................................................................................................................ 0.20-0.40 mm (0.008-0.016 inch)
Ring Gap, Second ...................................................................................................................................................... 0.35-0 55 mm (0.014-0.022 inch)
Ring Gap, Oil Rails .................................................................................................................................................... 0.25-0.76 mm (0.010-0.030 inch)
Piston, Engine
Piston Diameter @ 14.5 mm up ................................................................................................................... 85.967-85.982 mm (13.3845-3.3851 inch)
Piston to Bore Clearance .................................................................................................................................... 0.010-0.041 mm (0.0004-0.0016 inch)
Piston Weight ..................................................................................................................................................................................................................
Piston Height .......................................................................................................................................................................... Max. 0.9 mm-below deck
Piston Pin Bore I.D. ....................................................................................................................................... 20.002-20.007 mm (0.7875-0.7877 inch)
Ring Groove Width, Top ....................................................................................................................................... 1.23-1.25 mm (0.0484-0.0492 inch)
Ring Groove Width, Second .................................................................................................................................. 1.52-1.54 mm (0.0598-0.0606 inch)
Ring Groove Width, Oil Control ........................................................................................................................... 2.52-2.54 mm (0.0992-0.1000 inch)
Piston Ring Thickness, Top ............................................................................................................................ 1.170-1.190 mm (0.0461-0.0469 inch)
Piston Ring Thickness, Second .......................................................................................................................... 1.471-1.490 mm (0.0579-0.0587 inch)
Piston Ring Thickness, Oil Control Rail ................................................................................................................... 0.43 mm max. (0.0169 in max.)
Piston Ring Thickness, Oil Control Spacer ....................................................................................................... 1.574-1.651 mm (0.0620-0.0650 inch)
Ring to Groove Clearance, Top ............................................................................................................................. 0.04-0.08 mm (0.0015-0.0031 inch)
Ring to Groove Clearance, Second .................................................................................................................... 0.030-0.069 mm (0.0012-0.0027 inch)
Ring to Groove Clearance, Oil Control ............................................................................................................. 0.090-0.106 mm (0.0035-0.0042 inch)
Ring Gap, Top ............................................................................................................................................................ 0.20-0.40 mm (0.008-0.016 inch)
Ring Gap, Second ...................................................................................................................................................... 0.35-0 55 mm (0.014-0.022 inch)
Ring Gap, Oil Rails .................................................................................................................................................... 0.25-0.76 mm (0.010-0.030 inch)
General
Overhaul
General
Overhaul
Tightening Sequence
Cylinder Head

Exhaust Manifold

Camshaft Housing
Cam Cover to Cylinder Head Bolt ................................................................................................................................................. 10 Nm (89 inch lbs.)
Cam Cover to Ground Cable Bolt .................................................................................................................................................. 10 Nm (89 inch lbs.)
Cam Cover to Ground Cable Stud ................................................................................................................................................. 10 Nm (89 inch lbs.)
Rocker Arm Assembly
Rocker Arm Bolts .............................................................................................................................................................................. 25 Nm (19 ft. lbs.)
Stationary Lash Adjuster Bore I.D. ............................................................................................................. 12.013-12.037 mm (0.4730-0.4739 inch)
Stationary Lash Adjuster O.D. ....................................................................................................................... 11.986-12.000 mm (0.0005-0.0020 inch)
Stationary Lash Adjuster Clearance ................................................................................................................ 0.013-0.051 mm (3.2210-3.2299 inch)
Valve Clearance
The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment.
Valve Cover
Rocker Arm Cover Bolts ................................................................................................................................................................ 10 Nm (89 inch lbs.)
Valve Guide
Valve Guide I.D., Intake .................................................................................................................................... 6.000-6.012 mm (0.2362-0.2367 inch)
Valve Guide I.D., Exhaust ................................................................................................................................. 6.000-6.012 mm (0.2362-0.2367 inch)
Valve Seat
Valve Seat Run-out ......................................................................................................................................................... 0.05 mm max. 0.0020 in max.
Valve Spring
Valve Spring Load @ 32.5 mm, Closed ............................................................................................................................. 245.0-271.0 N. - Eng. Spec.
Valve Spring Load @ 32.5 mm, Open ............................................................................................................................... 525.0-575.0 N. - Eng. Spec.
Valve, Intake/Exhaust
Valve Stem O.D., Intake .................................................................................................................................... 5.955-5.970 mm (0.2344-0.2355 inch)
Valve Stem O.D., Exhaust ................................................................................................................................. 5.935-5.950 mm (0.2337-0.2343 inch)
Stem to Guide Clearance, Intake ........................................................................................................................ 0.030-0.057 mm (0.0012-0.0022 inch)
Stem to Guide Clearance, Exhaust ..................................................................................................................... 0.050-0.077 mm (0.0020-0.0026 inch)
Valve Stem Installed Heights ............................................................................................................................................................. Check and Record
Valve Face Run-out ...................................................................................................................................................... 0.04 mm max. 0.0016 in max.
Drive Belt Tensioner
Drive Belt Tensioner Bolt .................................................................................................................................................................. 45 Nm (33 ft. lbs.)
Engine Mount
Engine Bracket to Mount Bolt ........................................................................................................................................................... 60 Nm (44 ft. lbs.)
Final Pass 90 degrees
Engine Mount to Body Nut ............................................................................................................................................................... 75 Nm (55 ft. lbs.)
Engine Mount Strut Bolts ................................................................................................................................................................ 100 Nm (74 ft. lbs.)
Final Pass 90 degrees
Engine Mount Strut Bracket Bolts ..................................................................................................................................................... 66 Nm (49 ft. lbs.)
Engine Oil Dip Stick - Dip Stick Tube

Oil Fill Tube ...................................................................................................................................................................................... 50 Nm (37 ft. lbs.)
Dipstick Guide to Intake Manifold Bolt ......................................................................................................................................... 10 Nm (89 inch lbs.)
Engine Oil Drain Plug

Oil Pan Drain Bolt .............................................................................................................................................................................. 26 Nm (19 ft lbs)
Intake Manifold
Intake Manifold to Cylinder Head Bolt .......................................................................................................................................... 10 Nm (89 inch lbs.)

Intake Manifold to Cylinder Head Nut .......................................................................................................................................... 10 Nm (89 inch lbs.)
Intake Manifold to Cylinder Head Stud ........................................................................................................................................... 6 Nm (53 inch lbs.)
Lifter / Lash Adjuster, Valve

Lifter Guide .................................................................................................................................................................................... 11 Nm (97 inch lbs.)
Stationary Lash Adjuster Bore I.D. ................................................................................................................ 12.013-12.037 mm (0.4730-0.4739 inch)
Stationary Lash Adjuster O.D. ....................................................................................................................... 11.986-12.000 mm (0.0005-0.0020 inch)
Stationary Lash Adjuster Clearance ................................................................................................................ 0.013-0.051 mm (3.2210-3.2299 inch)
Oil Filter Adapter

Oil Filter Adapter .............................................................................................................................................................................. 35 Nm (26 ft. lbs.)
Oil Filter Housing

Oil Filter Housing Cover ................................................................................................................................................................... 22 Nm (16 ft. lbs.)
Oil Filter, Engine
Oil Filter Housing Cover ...................................................................................................................................................................... 25 Nm (18 ft lb)
Oil Pan, Engine
Oil Pan to Block Bolts ........................................................................................................................................................................ 25 Nm (18 ft lbs)

Oil Pressure Sender
Oil Pressure Switch ........................................................................................................................................................................ 10 Nm (89 inch lbs.)
Oil Pump Cover

Oil Pump Cover Bolt ........................................................................................................................................................................ 6 Nm (53 inch lbs.)
Oil Pump Drive Shaft

Oil Pump Drive Assembly ................................................................................................................................................................. 25 Nm (18 ft. lbs.)
Oil Pump, Engine

Oil Pump Gerotor Cover-Rear-Bolt ..................................................................................................................................................... 6 Nm (53 in.lbs.)
Oil Pump Pressure Relief Valve Plug ................................................................................................................................................ 40 Nm (80 ft. lbs.)
Oil Pump and Components
Gerotor Pocket I.D. ........................................................................................................................................................................................................
Outer Element O.D. ........................................................................................................................................................................ 41.8 mm (1.65 inch)
Outer Element Clearance ............................................................................................................................................................ 0.035 mm (0.012 inch)
Gerotor Pocket Depth ......................................................................................................................................................................................................
Outer Element Thickness ............................................................................................................................................................ 14.0 mm (0.5512 inch)
Inner Element Thickness .......................................................................................................................................................... 13.98 mm (0.5504 inch)
Pocket Depth Clearance, Outer .......................................................................................................................................................................................
Pocket Depth Clearance, Inner ........................................................................................................................................................................................
Pressure Relief Valve I.D. ...............................................................................................................................................................................................
Pressure Relief Valve O.D. .............................................................................................................................................................................................
Pressure Relief Valve Clearance .....................................................................................................................................................................................
Pressure Relief Valve Spring Working Length .......................................................................................................................... 56.5 mm (2.2244 inch)
Pressure Relief Valve Tension - Length .........................................................................................................................................................................
Crankshaft Pulley Bolt
First Pass ...................................................................................................................................................................................... 100 Nm (74 ft. lbs.)
Camshaft Timing Chain Tensioner .................................................................................................................................................... 75 Nm (55 ft. lbs.)
Timing Chain
Timing Chain Oil Nozzle Bolt ....................................................................................................................................................... 10 Nm (89 inch lbs.)
Timing Chain Length ............................................................................................................................. 477.367-477.817 mm (18.7940-18.8117 inch)
Timing Chain Guide

Chain Guide Plug .............................................................................................................................................................................. 80 Nm (59 ft. lbs.)
Timing Fixed Chain Guide Bolt ..................................................................................................................................................... 10 Nm (89 inch lbs.)
Timing Upper Chain Guide Bolt .................................................................................................................................................... 10 Nm (89 inch lbs.)
Timing Adjustable Chain Guide Bolt ............................................................................................................................................. 10 Nm (89 inch lbs.)
Timing Chain Tensioner

Camshaft Timing Chain Tensioner .................................................................................................................................................... 75 Nm (55 ft. lbs.)
Timing Cover
Front Cover to Block Bolt ................................................................................................................................................................. 25 Nm (18 ft. lbs.)
Exhaust Manifold
Exhaust Manifold to Cylinder Head Nut ............................................................................................................................................. 12 Nm (9 ft. lbs.)

Exhaust Manifold to Cylinder Head Stud ...................................................................................................................................... 10 Nm (89 inch lbs.)
Exhaust Manifold Pipe Flange Stud .................................................................................................................................................. 16 Nm (12 ft. lbs.)
Heat Shield to Exhaust Manifold Bolt ........................................................................................................................................... 10 Nm (89 inch lbs.)
Exhaust Pipe
Exhaust Manifold Pipe Bolt .............................................................................................................................................................. 45 Nm (33 ft. lbs.)
Intermediate Pipe Bolt ....................................................................................................................................................................... 30 Nm (22 ft. lbs.)
Muffler
Muffler Hanger Bolt .......................................................................................................................................................................... 16 Nm (12 ft. lbs.)
Flex Plate
Flexplate (AMT) Bolt
First Pass ........................................................................................................................................................................................... 53 Nm (39 lb ft)
Fastener Tightening Specifications - Part 1
Fastener Tightening Specifications - Part 2
Compressor Clutch
Air Gap Between The Pulley And The Drive Plate
0.3-0.6 mm (0.012-0.024 in) Air Gap
Ignition System Specifications
Firing Order
Firing Order ........................................................................................................................................................................................................ 1-3-4-2
For number 1 cylinder location, See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Ignition Timing/Number One C
Spark Plug
Spark Plug Gap ................................................................................................................................................................ 1.1-0.95 mm (0.043-0.037 in)
Spark Plug Torque ............................................................................................................................................................................. 20 Nm (15 ft. lbs.)
Unit Repair
Specifications
Shim Specifications
Steering System - Fastener Tightening Specifications
Ignition Switch
IGNITION SWITCH
Ignition Switch Assembly (3) Retaining Screws (2) Steering Column (1)
Retainer Screws ...................................................................................................................................................................................... 4 Nm (36 lb in)
Front Suspension
Rear Suspension
Trim Height Specifications
Z Height
D Height
Axle Nut
Drive Axle Nut ................................................................................................................................................................................. 200 N.m (148 lb ft)
Wheel Stud / Lug Nut

Wheel Nuts .................................................................................................................................................................................... 140 Nm (100 ft. lbs.)
Windows
Line Pressure Part (1 Of 2)
Line Pressure Part (2 Of 2)
Compression Check
Compression Pressure Minimum ........................................................................................................................................................ 689 kPa (100 psi)
The lowest reading cylinder should not be less than 70 percent of the highest
Altitude Vs Barometric Pressure
Engine Oil Pressure

Oil Pressure @ 1,000 RPM ........................................................................................................................................... 344.75-551.60 Kpa (50-80 Psi)
Fuel Pressure
Fuel Pressure (Key On, Engine Off) ........................................................................................................................................ 345-414 kPa (50-60 psi)
Fuel Pump
Fuel Pressure (Key On, Engine Off) ........................................................................................................................................ 345-414 kPa (50-60 psi)
Power Steering Pump
Thermostat, Engine Cooling

Thermostat Open Temperature .................................................................................................................................................................. 82°C (180°F)
Inflation Pressure Converrsion (Kilopascals To PSI)
Fluid Capacity Specifications
Fluid - A/T
Transmission Fluid
Pan Removal .............................................................................................................................................................................................. 6.5L (6.9 Qt)
Overhaul ..................................................................................................................................................................................................... 9.0L (9.5 Qt)
Dry ......................................................................................................................................................................................................... 12.2L (12.9 Qt)
Cooling System Capacity 8.6 qt (US)
Engine Oil
Engine Oil
With Filter Change ...................................................................................................................................................................................... 4.7L (5.0 Qt)
NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level.
Fuel Tank
Fuel Tank Capacity .............................................................................................................................................................................. 53.4 L (14.1 gal)
Maintenance
FLUID CAPACITY/LEVELS
Note that ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level.
Lubrication Specifications
Fluid - M/T
Transmission Fluid ..................................................................................................................................................................................... 1.7L (1.8 Qt)
Power Steering Fluid
Notice: Refer to Using Proper Power Steering Fluid Notice in Service Precautions.
See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Using Proper Power Steering Fluid Notice
NOTE: Fluid capacity specification not supplied by manufacturer.

See: Steering and Suspension/Steering/Service and Repair/Checking and Adding Power Steering Fluid
Refrigerant Capacity
Refrigerant Capacity
Refrigerant Capacity 1.5 lbs.
Refrigerant System Capacities (L61)
Type Dexron(R)-III Automatic Transmission Fluid or Equivalent
Fluid - A/T
Transmission Fluid Type
Type .................................................................................................................................................................................... DEXRON III or Equivalent

BRAKE FLUID
Delco Supreme 11 ...................................................................................................................................... GM P/N 12377967 (Canadian P/N 992667)
- or equivalent -
DOT-3 brake fluid
CAUTION: The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to
Hydraulic Brake System Delco Supreme 11 Brake Fluid GM Part No. 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid.
Hydraulic Clutch System Hydraulic Clutch Fluid (GM Part No. 12345347, in Canada 10953517, or equivalent DOT-3 brake fluid).
Coolant
ENGINE COOLANT
The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,0
A 50/50 mixture of clean, drinkable water (if the water in your area is of poor quality, it is recommended you use distilled or de-ionized water) and D
- Give freezing protection down to -34°F (-37°C).
- Give boiling protection up to 265°F (129°C).
- Protect against rust and corrosion.
- Help keep the proper engine temperature.
- Let the warning lights and gages work as they should.
NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant m
WHAT TO USE
Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mix
CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil be
NOTICE If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by yo
If you have to add coolant more than four times a year, check your cooling system.
NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be har
Engine Oil
Engine Oil
API Classification .................................................................................................................................................................. Look for Starburst Symbol

Grade ................................................................................................................................................................................................. 5W-30 (preferred)
Above -18° C (0° F) ........................................................................................................................................................... 10W-30, 5W-30 (preferred)
Below -29° C (-20° F) .......................................................................................................................................... 5W-30 synthetic (preferred) , 0W-30
Fuel
GASOLINE OCTANE
Use regular unleaded gasoline with a posted octane of 87 or higher. If the octane is less than 87, you may get a heavy knocking noise when you dr
ADDITIVES
To provide cleaner air, all gasoline in the United States are now required to contain additives that will help prevent engine and fuel system deposit
NOTICE: Your vehicle was not designed for fuel that contains methanol. Don't use fuel containing methanol. It can corrode metal parts in your f
Some gasoline that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tr
CALIFORNIA FUEL
If your vehicle is certified to meet California Emission Standards (see the underhood emission control label), it is designed to operate on fuels that
A Recommended Fluids and Lubricants

RECOMMENDED FLUIDS AND LUBRICANTS
Look for and use ONLY the oils, fluids and fuel that meet GM Specification. Oil or fluid that does not have the correct specification designation c
Floor Shift Linkage
FLOOR SHIFT LINKAGE
Lubriplate lubricant aerosol, GM P/N 12346293 in Canada 992723 or lubricant meeting the requirements of NLGI # 2, category LB or GC-LB.
Hinges and Locks
HINGES AND LOCKS
Multi-Purpose lubricant Superlube(R), GM P/N 12346241 or equivalent.
Key Lock Cylinders
KEY LOCK CYLINDERS
Multi-Purpose lubricant Superlube(R), GM P/N 12346241 (Canadian P/N 10953474) or equivalent.
Misc.. Linkage, Latches, Pivots and Spring Anchors
MISC. LINKAGE, LATCHES, PIVOTS AND SPRING ANCHORS
Lubriplate lubricant aerosol, GM P/N U.S. 12346293, in Canada 992723 or lubricant meeting the requirements of NLGI # 2, category LB or GC-L
Parking Brake Cable Guides
PARKING BRAKE CABLE GUIDES
Chassis lubricant, GM P/N 12377985 or lubricant meeting the requirements of NLGI # 2, category LB or GC-LB.
Weatherstrip Conditioning
WEATHERSTRIP CONDITIONING
Dielectric Silicone Grease, GM P/N U.S. 12345579, in Canada 1974984, or equivalent.
Windshield Washer Solvent
WINDSHIELD WASHER SOLVENT
GM Optikleen(R) washer solvent, GM P/N 1051515 (Canadian P/N 992667) or equivalent.
Type DEXRON-III (R) Automatic Transmission Fluid or Equivalent
Fluid - M/T
Transmission Fluid ......................................................................................................................................................................................... Dexron III
Power Steering Fluid
Fluid Type
.......... GM Power Steering Fluid GM P/N 1052884 - 1 pint (Canadian P/N 993294), 1050017 - 1 quart, (Canadian P/N 992646) or equivalent.
Refrigerant Type
Refrigerant Type
Air Conditioning Refrigerant R134a
Refrigerant Oil
Refrigerant Oil
Refrigerant Oil (R-134a system) PAG oil

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2003 Chevrolet Cavalier L4-2.2L VIN F Copyright © 2012, ALLDATA 10.

Transmission Fluid Temperature (TFP) Sensor Specifications

Transmission Fluid Pressure (TFP) Manual Valve Position Switch Logic

Transmission Range Switch Logic

Voltage and Amperage

Temperature Vs Resistance Part 1

Temperature Vs Resistance Part 2

Fastener Tightening Specifications

Fastener Tightening Specifications

Fastener Tightening Specifications

Reverse Clutch Backing Plate Specifications

Fluid Pan, A/T

Frame and Underbody

Body Front End

Body Rear End

Exterior Moulding / Trim

Fastener Tightening Specifications

Dashboard / Instrument Panel

Brake Rotor Diameter .................................................................................................................................................................. 10.197 in (259.0 mm)

Brake Rotor Discard Thickness* .................................................................................................................................................... 0.736 in (18.70 mm)

Brake Rotor Maximum Allowable Scoring ...................................................................................................................................... 0.059 in (1.50 mm)

Drum Brake Component Specifications

Park Brake Warning Lamp Switch Mounting Screw 26 ft. lbs.

Parking Brake Cable Guide Mounting Nuts 81 inch lbs.

Parking Brake Level Mounting Nuts 18 ft. lbs.

Fastener Tightening Specifications

clutch cover to flywheel bolts ............................................................................................................................................................ 24 Nm (18 ft. lbs.)

Fastener Tightening Specifications Part 1

Fastener Tightening Specifications Part 2

ENGINE COOLING / Fastener Tightening Specifications

Engine - Coolant Temperature Sensor/Switch

Radiator Cooling Fan Motor

Thermostat Housing, Engine Cooling

General Engine Specifications

Engine Mechanical Specifications

Camshaft Bearing Caps

Thread Repair Specifications

Engine Block-Front View

Engine Block-Back View

Engine Block-Left Side View

Engine Block-Bottom View

Engine Block-Right Side View

Engine Block-Top View

Lower Crankcase - Front View

Lower Crankcase-Back View

Lower Crankcase - Bottom View

Lower Crankcase - Left View

Lower Crankcase-Right View

Cylinder Head-Top View

Cylinder Head-Intake Manifold Deck View

Cylinder Head-Exhaust Manifold Deck View

Cylinder Head-Front View

Cylinder Head-Back View

Cylinder Head-Bottom View

Metric-English Conversion Factors

Camshaft Bearing Cap Bolt ............................................................................................................................................................ 10 Nm (89 inch lbs.)

Engine Mechanical Specifications

Camshaft Bearing Caps

Thread Repair Specifications