Cavalier, Sunfire 2001-2005

Electric Engine Fan

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Cooling Fan Connectors



Removal & Installation
2.2L& 2.4L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the hood close out filler retainers.
  4.  
  5. Remove the hood close out filler panel.
  6.  
  7. Remove the upper radiator mount bolts.
  8.  
  9. Remove the upper two hood latch support bolts.
  10.  
  11. Remove the two lower hood latch support bolts.
  12.  
  13. Raise the vehicle.
  14.  
  15. Remove the cooling fan mounting bolt.
  16.  
  17. Disconnect the electrical connector from the cooling fan. Remove the cooling fan assembly.
  18.  

To install:

  1. Install the cooling fan assembly.
  2.  
  3. Connect the electrical connector to the cooling fan.
  4.  
  5. Install the cooling fan mounting bolt. Tighten the bolt to 53 inch lbs. (6 Nm).
  6.  
  7. Lower the vehicle.
  8.  
  9. Install the lower two hood latch support bolts. Tighten the bolts to 20 ft. lbs. (27 Nm).
  10.  
  11. Install the two upper hood latch support bolts. Tighten the two upper hood latch support bolts to 80 inch lbs. (9 Nm).
  12.  
  13. Install the upper radiator mount bolts. Tighten bolts to 89 inch lbs. (10 Nm).
  14.  
  15. Install the hood close out filler panel.
  16.  
  17. Install the hood close out filler panel retainers.
  18.  

Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the hood close out filler retainers.
  4.  
  5. Remove the hood close out filler panel.
    CAUTION
    Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying power to a sensor:



    Click image to see an enlarged view

    Fig. Remove the hood close out filler retainers and the hood close out filler panel




    1. Remove any dirt, grease, etc. from the mounting surface
    2.  
    3. Position the sensor horizontally on the mounting surface
    4.  
    5. Point the arrow on the sensor toward the front of the vehicle
    6.  
    7. Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value.
    8.  

  6.  
  7. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs.
  8.  
  9. Disable the air bag sensor.
  10.  
  11. Remove the upper radiator mount bolts.
  12.  
  13. Remove the upper 2 hood latch support bolts (2).
  14.  
  15. Remove the 2 lower hood latch support bolts (4).
  16.  
  17. Raise the vehicle.

    Click image to see an enlarged view

    Fig. Remove the cooling fan mounting bolt

  18.  
  19. Remove the cooling fan mounting bolt.
  20.  
  21. Disconnect the electrical connector from the cooling fan.
  22.  
  23. Remove the cooling fan assembly.
  24.  

To install:

  1. Install the cooling fan assembly.
  2.  
  3. Connect the electrical connector to the cooling fan.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4.  
  5. Install the cooling fan mounting bolt and tighten the bolt to 53 lb inches (6 Nm).
  6.  
  7. Lower the vehicle.
  8.  
  9. Install the lower 2 hood latch support bolts and tighten the bolts) to 20 ft. lbs. (27 Nm).
  10.  
  11. Install the 2 upper hood latch support bolts and tighten the bolts to 80 lb inches (9 Nm).
  12.  
  13. Install the upper radiator mount bolts and tighten bolts to 89 lb inches (10 Nm).
  14.  
  15. Engage the air bag sensor.
  16.  
  17. Install the hood close out filler panel.
  18.  
  19. Install the hood close out filler panel retainers.
  20.  
  21. Connect the negative battery cable.
  22.  

 
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