SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 143 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSRADIATOR REPLACEMENTINSTALLATION PROCEDURE
2001 Chevrolet Cavalier LS, 2.4 T

Installation Procedure

2001 Chevrolet Cavalier LS, 2.4 TSECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the radiator assembly to the vehicle. See Figure.
  2. Install the condenser to the radiator.
  3. Install condenser to radiator mounting bolts (2).
  4. Use the J 38185  in order to install the surge tank hose to the radiator.
    Fig 1: Connecting Surge Tank Hose At Radiator
    G01580933Courtesy of GENERAL MOTORS CORP.
  5. Route the forward discriminating sensor harness. Refer to ZONE 1 .
  6. Raise the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  7. Install the lower transmission oil cooler line to the radiator.

    Tighten 

    Tighten the line to 36 N.m (27 lb. ft).

    Fig 2: Connecting Transmission Oil Cooler Lines At Radiator
    G01580934Courtesy of GENERAL MOTORS CORP.
  8. Install the cooling fan assembly. Refer to Cooling Fan Replacement - Electric .
  9. Use the J 38185  in order to install the radiator outlet hose to the radiator.
    Fig 3: Connecting Radiator Hoses At Radiator
    G01580935Courtesy of GENERAL MOTORS CORP.
  10. Connect the forward discriminating sensor harness connector. Refer to ZONE 1 .
  11. Lower the vehicle.
  12. Use the J 38185  in order to connect the radiator inlet hose to the radiator.
  13. Install the upper transmission oil cooler line to the radiator.

    Tighten 

    Tighten the upper transmission oil cooler line to 36 N.m (27 lb. ft).

  14. Install the upper radiator mount bolts (1) to the upper tie bar.
    Fig 4: Installing Upper Radiator Mount Bolts
    G01580937Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the bolts to 10 N.m (89 lb. in).

  15. Install the hood latch support. Refer to HOOD LATCH SUPPORT REPLACEMENT .
  16. Install the right and the left headlamp assemblies Refer to HEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT (PONTIAC) in Lighting Systems.
  17. Install and adjust the hood latch assembly. Refer to HOOD LATCH REPLACEMENT .
  18. Fill the cooling system. Refer to Draining and Filling Cooling System (L61) .
  19. Enable the SIR system. Refer to ZONE 1 .
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.