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HOMESERVICE MANUALSCHEVROLET2002CAVALIER BASE, 4D SEDAN, 2.4 TREPAIR AND DIAGNOSISENGINE MECHANICALCOOLING SYSTEM (MECHANICAL)ENGINE COOLING SYSTEMREPAIR INSTRUCTIONSRADIATOR REPLACEMENTREMOVAL PROCEDURE
2002 Chevrolet Cavalier Base, 4D Sedan, 2.4 T

Removal Procedure

2002 Chevrolet Cavalier Base, 4D Sedan, 2.4 TSECTION Removal Procedure
  1. Disable the SIR system. Refer to DISABLING & ACTIVATING AIR BAG SYSTEM .
  2. Drain the cooling system. Refer to DRAINING & FILLING COOLING SYSTEM - 2.2L (L61) .
  3. Remove the hood latch.
  4. Remove the right and left headlamp assemblies.
  5. Remove the radiator upper mounting bolts (1) and the upper radiator mounts (2).
    Fig 1: Radiator Upper Mounting Bolts & Upper Radiator Mounts
    G01778030Courtesy of GENERAL MOTORS CORP.
  6. Raise the vehicle.
  7. Disconnect the forward discriminating sensor harness. Refer to DISABLING & ACTIVATING AIR BAG SYSTEM .
  8. Remove the cooling fan assembly. Refer to Cooling Fan Replacement - Electric .
  9. Use the J 38185  in order to reposition the radiator outlet hose clamp from the radiator.
  10. Remove the radiator outlet hose from the radiator.
    Fig 2: Radiator Outlet Hose
    G01778031Courtesy of GENERAL MOTORS CORP.
  11. Remove the lower transmission oil cooler line from the radiator.
  12. Lower the vehicle.
  13. Remove the hood latch support bracket and the forward discriminating sensor with the harness.
  14. Remove the upper transmission oil cooler line from the radiator.
  15. Use the J 38185  in order to reposition the radiator inlet hose from the radiator.
  16. Remove the surge tank inlet hose and the clamp (1) from the radiator.
    Fig 3: Surge Tank Inlet Hose
    G01778033Courtesy of GENERAL MOTORS CORP.
  17. Remove the condenser from the radiator, if equipped. You are not required to discharge the A/C System.
  18. Remove the radiator assembly from the vehicle.
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.