Cavalier, Sunfire 2001-2005

Removal & Installation

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  1. Disable the SIR system, as outlined in the Chassis Electrical Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the hood latch.
  6.  
  7. Remove the right and left headlamp assemblies.

    Click image to see an enlarged view

    Fig. Remove the radiator upper mounting bolts (1) and the upper radiator mounts (2)

  8.  
  9. Remove the radiator upper mounting bolts and the upper radiator mounts.
  10.  
  11. Raise the vehicle.
  12.  
  13. Disconnect the forward discriminating sensor harness.
  14.  
  15. Remove the cooling fan assembly.
  16.  
  17. Use the special tool J38185 in order to reposition the radiator outlet hose clamp from the radiator.

    Click image to see an enlarged view

    Fig. Remove the radiator outlet hose and the lower transmission oil cooler line from the radiator

  18.  
  19. Remove the radiator outlet hose from the radiator.
  20.  
  21. Remove the lower transmission oil cooler line from the radiator.
  22.  
  23. Lower the vehicle.
  24.  
  25. Remove the hood latch support bracket and the forward discriminating sensor with the harness.
  26.  
  27. Remove the upper transmission oil cooler line from the radiator.
  28.  
  29. Use the special tool J38185 in order to reposition the radiator inlet hose clamp from the radiator.
  30.  
  31. Remove radiator inlet hose from radiator.
  32.  
  33. Remove the surge tank inlet hose and the clamp from the radiator.
  34.  
  35. Remove condenser to radiator mounting bolts.
  36.  
  37. Remove the condenser from the radiator, if equipped. The radiator can be removed without discharging the A/C System.
  38.  
  39. Remove the radiator assembly from the vehicle.
  40.  

To install:

  1. Install the radiator assembly to the vehicle.
  2.  
  3. Install the condenser to the radiator.
  4.  
  5. Install condenser to radiator mounting bolts.
  6.  
  7. Use the special tool J38185 in order to install the surge tank hose to the radiator.
  8.  
  9. Route the forward discriminating sensor harness.
  10.  
  11. Raise the vehicle.
    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.

  12.  
  13. Install the lower transmission oil cooler line to the radiator and tighten the line to 27 ft. lbs. (36 Nm).
  14.  
  15. Install the cooling fan assembly.
  16.  
  17. Install the radiator outlet hose to the radiator.
  18.  
  19. Use the special tool J38185 in order to reposition the radiator outlet hose clamp.
  20.  
  21. Connect the forward discriminating sensor harness connector.
  22.  
  23. Lower the vehicle. install the radiator inlet hose to the radiator.
  24.  
  25. Use the special tool J38185 in order to reposition the radiator inlet hose clamp.
  26.  
  27. Install the upper transmission oil cooler line to the radiator and tighten the upper transmission oil cooler line to 27 ft. lbs. (36 Nm).
  28.  
  29. Install the upper radiator mount bolts to the upper tie bar and tighten the bolts to 89 lb inches (10 Nm).
  30.  
  31. Install the hood latch support.
  32.  
  33. Install the right and the left headlamp assemblies.
  34.  
  35. Install and adjust the hood latch assembly.
  36.  
  37. Fill the cooling system.
  38.  
  39. Enable the SIR system, as outlined in the Chassis Electrical Section.
  40.  

 
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