Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2002CAVALIER BASE, 4D SEDAN, 2.4 TREPAIR AND DIAGNOSISENGINE MECHANICALCOOLING SYSTEM (MECHANICAL)ENGINE COOLING SYSTEMREPAIR INSTRUCTIONSRADIATOR REPLACEMENTINSTALLATION PROCEDURE
2002 Chevrolet Cavalier Base, 4D Sedan, 2.4 T
Installation Procedure
2002 Chevrolet Cavalier Base, 4D Sedan, 2.4 TSECTION Installation Procedure
- Install the radiator assembly to the vehicle.
- Install the condenser to the radiator.
- Use the J 38185 in order to install the surge tank hose to the radiator.
- Route the forward discriminating sensor harness. Refer to FRONT END DISCRIMINATING SENSOR .
- Raise the vehicle.
- Install the lower transmission oil cooler line to the radiator. Tighten the line to 36 N.m (27 ft lbs).
- Install the cooling fan assembly. Refer to Cooling Fan Replacement - Electric .
- Use the J 38185 in order to Install the radiator outlet hose to the radiator.
- Connect the forward discriminating sensor harness connector. Refer to FRONT END DISCRIMINATING SENSOR .
- Lower the vehicle.
- Use the J 38185 in order to Connect the radiator inlet hose to the radiator.
- Install the upper transmission oil cooler line to the radiator. Tighten the upper transmission oil cooler line to 36 N.m (27 ft lbs).
- Install the upper radiator mount bolts (1) to the upper tie bar. Tighten the bolts to 10 N.m (89 in lbs).
- Install the hood latch support.
- Install the right and the left headlamp assemblies.
- Install and adjust the hood latch assembly.
- Fill the cooling system. Refer to DRAINING & FILLING COOLING SYSTEM - 2.2L (L61) .
- Enable the SIR system. Refer to DISABLING & ACTIVATING AIR BAG SYSTEM .
RENDER: 1.0x
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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.