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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 225 (ENGINE COOLING SYSTEM - 2.2L (L61))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 2004 Pontiac Sunfire and 2004 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.
  2. Install the condenser to the radiator.
    Fig 1: Identifying Radiator Condenser
    GM25811Courtesy of GENERAL MOTORS CORP.
  3. Install condenser to radiator mounting bolts (2).
  4. Use the J 38185  in order to install the surge tank hose (3) to the radiator.
    5. Fig 2: Identifying Radiaror Vent & Outlet Hoses
    GM1195908Courtesy of GENERAL MOTORS CORP.
  5. Route the forward discriminating sensor harness. Refer to SIR Disabling and Enabling Zone 1 in SIR.
  6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  7. Install the lower transmission oil cooler line to the radiator.

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

    Fig 3: Locating Lower Transmission Oil Cooler Line
    GM12063Courtesy of GENERAL MOTORS CORP.
  8. Install the cooling fan assembly. Refer to Cooling Fan Replacement - Electric .
  9. Install the radiator outlet hose (6) to the radiator.
  10. Use the J 38185  in order to reposition the radiator outlet hose clamp (7).
    11. Fig 4: View Of Surge Tank Components
    GM1172693Courtesy of GENERAL MOTORS CORP.
  11. Connect the forward discriminating sensor harness connector. Refer to SIR Disabling and Enabling Zone 1 in SIR.
  12. Lower the vehicle.
  13. install the radiator inlet hose (2) to the radiator.
  14. Use the J 38185  in order to reposition the radiator inlet hose clamp (1).
  15. 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).

    Fig 5: Locating Lower Transmission Oil Cooler Line
    GM12063Courtesy of GENERAL MOTORS CORP.
  16. Install the upper radiator mount bolts (1) to the upper tie bar.

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

    Fig 6: Locating Upper Radiator Mount Bolts
    GM25877Courtesy of GENERAL MOTORS CORP.
  17. Install the hood latch support. Refer to Hood Latch Support Replacement in Body Front End.
  18. Install the right and the left headlamp assemblies. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Pontiac) in Lighting Systems.
  19. Install and adjust the hood latch assembly. Refer to Hood Latch Replacement in Body Front End.
  20. Fill the cooling system. Refer to Draining and Filling Cooling System (L61) .
  21. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1 in SIR.
RENDER: 1.0x

NO RELATED

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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.