Engine Cooling System Chevrolet Cavalier III

Fastener Tightening Specifications

Fastener Tightening Specifications

Draining & Filling Cooling System - 2.2L (L61)

Note. If the procedure below is not followed a low or high coolant level condition and/or vehicle damage could result.

Draining Procedure

1. Park the vehicle on a level surface.
2. Remove the surge tank cap.
3. Raise and support the vehicle.
4. Place a drain pan under the drain cock.
5. Open the radiator drain cock.
6. Drain the cooling system.
7. Inspect the engine coolant for the following: Discolored - follow the flush procedure. Refer to «Flushing»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__flushing) . Normal in appearance - follow the filling procedure. If a complete block drain is required, remove the water pump drain plug.

Filling Procedure

Tools Required

J 26568 Coolant and Battery Tester

1. Close the radiator drain cock. Tighten to 2 N.m (18 in lbs).
2. Install the water pump drain plug if necessary. Tighten the water pump drain plug to 22 N.m (16 in lbs).
3. Lower the vehicle.
4. Fill the cooling system.
5. Slowly add a mixture of 50/50 DEX-COOL antifreeze and deionized water to the cooling system until the coolant level reaches and maintains the top of the surge tank label. Important: It is necessary to maintain the coolant level at the top of the surge tank label to insure all the air has been purged from the cooling system.
6. Install surge tank cap.
7. Start the engine.
8. Run the engine at 2,000-2,500 RPM until engine reaches normal operating temperature.
9. Allow the engine to idle for 3 minutes.
10. Shut the engine off.
11. Allow the engine to cool.
12. Top off the coolant as necessary.
13. Inspect the cooling system for leaks.
14. Rinse away any excess coolant from the engine and the engine compartment.
15. Inspect the concentration of the engine coolant using J 26558 .

Flushing

Important: Do not use a chemical flush.

Store used coolant in the proper manner, such as in a used engine coolant holding tank. Do not pour used coolant down a drain. Ethylene glycol antifreeze is a very toxic chemical. Do not dispose of coolant into the sewer system or ground water. This is illegal and ecologically unsound.

Various methods and equipment can be used to flush the cooling system. If special equipment is used, such as a back flusher, follow the manufacturer's instruction. However, always remove the thermostat before back flushing the system.

1. Block the drive wheels.
2. Place the transmission in park (P) or neutral (N).
3. Engage the park brake.
4. Run the engine until the thermostat opens.
5. Stop the engine.
6. Follow the drain and fill procedure using only clean drinkable water. Repeat the procedure if necessary, until the fluid is nearly colorless. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
7. Fill the coolant reservoir to the FULL HOT mark.
8. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Radiator Cleaning

Note. The radiator fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer.

Important: Remove bugs, leaves, dirt and other debris by blowing compressed air through the engine side of the radiator.

1. Some conditions may require the use of warm water and a mild detergent.
2. Clean the A/C condenser fins.
3. Clean between the A/C condenser and radiator.
4. Clean the radiator cooling fins.
5. Straighten any damaged cooling fins.

Surge Tank Replacement

Tools Required

J 38185 Hose Clamp Pliers

Scheme 1

1. Raise and support the vehicle.
2. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) . Lower the vehicle.
3. Disconnect the low coolant sensor electrical connector.
4. Remove the low coolant sensor electrical harness from the retainer.
5. Use the J 38185 in order to Reposition the surge tank outlet hose clamp from the surge tank (1).
6. Remove the surge tank outlet hose from the surge tank (1).
7. Use the J 38185 in order to Reposition the engine vent hose clamp from the surge tank (3).
8. Remove the engine vent hose from the surge tank (3).
9. Use the J 38185 in order to Reposition the radiator vent hose clamp from the surge tank.
10. Remove the radiator vent hose from the surge tank.
11. Remove the radiator surge tank mounting bolt.
12. Remove the surge tank.

Installation Procedure

1. Install the surge tank.
2. Install the surge tank mounting bolt. Tighten the bolt to 10 N.m (89 in lbs).
3. Install the radiator vent hose to the surge tank.
4. Use the J 38185 in order to Reposition the radiator vent hose clamp to the surge tank.
5. Install the engine vent hose to the surge tank (3).
6. Use the J 38185 in order to Reposition the engine vent hose clamp to the surge tank.
7. Install the surge tank outlet hose to the surge tank (1).
8. Use the J 38185 in order to Reposition the surge tank outlet hose clamp to the surge tank.
9. Install the low coolant electrical connector.
10. Fill the cooling system at the radiator surge tank. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Radiator Hose Replacement - Inlet (2.2L - L61)

Tools Required

J 38185 Hose Clamp Pliers

Removal Procedure

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Disconnect the electrical connector from the intake air temperature sensor.
3. Loosen the air duct clamp.
4. Remove the intake air duct resonator.
5. Use the J 38185 in order to Reposition the inlet hose clamp from the water outlet (1).
6. Remove the inlet hose from the water outlet.
7. Raise and suitably support the vehicle.
8. Use the J 38185 in order to Reposition the inlet hose clamp from the radiator.
9. Remove the inlet hose (1) from the radiator.

1. Install the inlet hose (1) to the radiator.
2. Use the J 38185 in order to Reposition the inlet hose clamp to the radiator.
3. Lower the vehicle.
4. Install the inlet hose to the water outlet (1).
5. Use the J 38185 in order to Reposition the inlet hose clamp to the water outlet.
6. Install the intake air duct resonator.
7. Tighten the air duct clamp.
8. Connect the electrical connector to the intake air temperature sensor.
9. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Radiator Hose Replacement - Inlet (2.2L - LN2)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 2

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Use the J 38185 in order to Reposition the radiator inlet hose clamps (1) from the radiator.
3. Remove the radiator inlet hose from the radiator.
4. Use the J 38185 in order to Reposition the radiator inlet hose clamps (1) from the engine.
5. Remove the radiator inlet hose from the engine.

Note. Make sure the reference marks on the hoses and the radiator are lined up. A twist on the hose would place strain on the radiator fitting which could cause the fitting to crack or break.

1. Install the radiator inlet hose (1) to the engine.
2. Use the J 38185 in order to Reposition the radiator inlet hose clamp to the engine.
3. Install the radiator inlet hose (1) to the radiator.
4. Use the J 38185 in order to Reposition the radiator inlet hose clamp to the radiator.
5. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Radiator Hose Replacement - Inlet (2.4L - LD9)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 3

1. Remove battery.
2. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
3. Use the J 38185 in order to Reposition the radiator inlet hose clamp from the water outlet.
4. Remove the radiator inlet hose from the water outlet.
5. Use the J 38185 in order to Reposition the radiator inlet hose clamp from the radiator.
6. Remove the radiator inlet hose from the radiator.

Note. Make sure the reference marks on the hoses and the radiator are lined up. A twist on the hose would place strain on the radiator fitting which could cause the fitting to crack or break.

1. Install the radiator inlet hose to the radiator.
2. Use the J 38185 in order to Reposition the radiator inlet hose clamp to the radiator.
3. Install the radiator inlet hose to the water outlet.
4. Use the J 38185 in order to Reposition the radiator inlet hose clamp to the water outlet.
5. Install battery.
6. Fill cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Radiator Hose Replacement - Outlet (2.2L - L61)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 4

Scheme 5

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Use the J 38185 in order to Reposition the outlet hose clamp from the cylinder head (2).
3. Remove the outlet hose from the cylinder head.
4. Raise and suitably support the vehicle.
5. Use the J 38185 in order to Reposition the outlet hose clamp from the radiator.
6. Remove the outlet hose (2) from the radiator.

1. Install the outlet hose (2) to the radiator.
2. Use the J 38185 in order to Reposition the outlet hose to the radiator.
3. Lower the vehicle.
4. Install the outlet hose to the cylinder head (2).
5. Use the J 38185 in order to Position the outlet hose to the cylinder head.
6. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Radiator Hose Replacement - Outlet (2.2L - LN2)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 6

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Use the J 38185 in order to Reposition the radiator outlet hose clamp from the radiator.
3. Remove the radiator outlet hose from the radiator.
4. Use the J 38185 in order to Reposition the radiator outlet hose clamp from the engine.
5. Remove the radiator outlet hose from the engine.
6. Use the J 38185 in order to Reposition the radiator outlet hose from the surge tank.
7. Remove the radiator outlet hose from the surge tank.

Note. Make sure the reference marks on the hoses and the radiator are lined up. A twist on the hose would place strain on the radiator fitting which could cause the fitting to crack or break.

1. Install the radiator outlet hose to the surge tank.
2. Use the J 38185 in order to Reposition the radiator outlet hose clamp to the surge tank.
3. Install the radiator outlet hose to the engine.
4. Use the J 38185 in order to Reposition the radiator outlet hose clamp to the engine.
5. Install the radiator outlet hose to the radiator
6. Use the J 38185 in order to Reposition the radiator outlet hose clamp to the radiator.
7. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Radiator Hose Replacement - Outlet (2.4L - LD9)

Tools Required

J 38185 Hose Clamp Pliers

Scheme 7

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Use the J 38185 in order to Reposition lower radiator hose clamp from the surge tank.
3. Remove lower radiator hose from surge tank.
4. Raise the vehicle.
5. Use the J 38185 in order to Reposition the radiator outlet hose clamp (1) from the radiator pipe (3).
6. Remove the radiator outlet hose (1) from the radiator pipe (3).
7. Use the J 38185 in order to Reposition the radiator outlet hose clamp from the radiator.
8. Remove the radiator outlet hose from the radiator.

Note. Make sure the reference marks on the hoses and the radiator are lined up. A twist on the hose would place strain on the radiator fitting which could cause the fitting to crack or break.

1. Install radiator outlet hose to the radiator.
2. Use the J 38185 in order to Reposition the radiator outlet hose clamp to the radiator.
3. Install the radiator outlet hose (1) to the radiator pipe (3).
4. Use the J 38185 in order to Reposition the radiator outlet hose clamp (1) to the radiator pipe (3).
5. Lower vehicle.
6. Install the radiator outlet hose to the surge tank.
7. Use the J 38185 in order to Reposition the radiator outlet hose clamp to the surge tank.
8. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Scheme 8

1. Disconnect the negative battery cable.
2. Remove upper filler panel.
3. Remove upper radiator mount bolts.
4. Remove upper bolts retaining hood latch bracket to core support
5. Raise the vehicle.
6. Remove the cooling fan mounting bolt.
7. Disconnect the electrical connector from the cooling fan.
8. Remove the cooling fan assembly.

1. Install the cooling fan assembly.
2. Connect the electrical connector to the cooling fan.
3. Install the cooling fan mounting bolt. Tighten the cooling fan mounting bolt to 6 N.m (53 in lbs).
4. Lower the vehicle.
5. Install upper bolts to retain hood latch bracket to core support.
6. Install upper radiator mount bolts. Tighten bolts to 10 N.m (89 in lbs).
7. Install upper filler panel.

Cooling Fan Relay Replacement

Tools Required

J 43244 Relay Puller Pliers

Scheme 9

1. Remove the underhood electrical center cover.
2. Using the J 43244 , remove the cooling fan relay.

Note. Installation of the proper relay is critical. If an enhanced relay - equipped with a diode - is installed into a position requiring a standard relay - equipped without a diode - excessive current will damage any components associated with the relay or its associated circuits.

1. Install the cooling fan relay.
2. Install the underhood electrical center cover.

Scheme 10

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Remove the exhaust manifold heat shield bolts and shield.
3. Remove the coolant inlet housing bolts through the exhaust manifold.
4. Raise the vehicle.
5. Remove the coolant inlet housing stud from the oil pan.
6. Remove the tire and wheel.
7. Remove the right engine splash shield.
8. Remove the transaxle-to-engine block brace bolts. Remove the brace.
9. Remove the radiator outlet pipe. Refer to «Radiator Pipe Replacement - Outlet»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system) .
10. Remove the thermostat.
11. Clean the mating surfaces.

1. Install the thermostat.
2. Install the radiator outlet pipe. Refer to «Radiator Pipe Replacement - Outlet»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Install the transaxle-to-engine block brace and secure with the bolts.
4. Install the right engine splash shield.
5. Install the tire and wheel.
6. Lower the vehicle.
7. Install the exhaust manifold heat shield and bolt. Tighten the exhaust manifold heat shield bolts to 14 N.m (10 ft lbs).
8. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
9. Inspect the system for leaks.

Scheme 11

Scheme 12

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Remove the lower radiator hose from thermostat outlet.
3. Remove the thermostat outlet bolts and outlet.
4. Remove the thermostat.
5. Clean the mating surfaces of the radiator outlet and the radiator outlet pipe.

1. Install the thermostat.
2. Install the thermostat outlet and bolts.
3. Install the coolant outlet attaching bolts. Tighten the thermostat outlet bolts to 14 N.m (10 ft lbs).
4. Install the lower radiator hose to thermostat outlet.
5. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
6. Inspect for leaks.

Scheme 13

Scheme 14

Scheme 15

1. If equipped with an automatic transmission, remove the exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT (2.2L -- VINS 4 & 5)»(ref-173560-S00900304272005031700000) .
2. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
3. Remove the thermostat housing to water pump feed pipe bolts.
4. Remove the thermostat housing to water pump feed pipe.
5. Remove the thermostat.

1. Install the thermostat.
2. Install the thermostat housing to water pump feed pipe.
3. Install the thermostat housing to water pump feed pipe bolt. Tighten the thermostat housing to water pump feed pipe bolt to 10 N.m (18 in lbs).
4. If equipped with an automatic transmission, install the exhaust manifold.
5. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Scheme 16

Scheme 17

Scheme 18

1. Partially drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Remove the exhaust manifold heat shield bolts.
3. Remove the exhaust manifold heat shield.
4. Remove the coolant air bleed pipe retaining bolt from the cylinder head.
5. Reposition the surge tank inlet hose clamp from the surge tank.
6. Remove the surge tank inlet hose from the surge tank.
7. Remove the air bleed pipe from the vehicle.

1. Install the air bleed pipe to the coolant outlet housing.
2. Install the surge tank hose to the surge tank.
3. Reposition the surge tank hose clamp to the surge tank.
4. Install the air bleed pipe, retaining. Tighten the air bleed pipe bolt to 14 N.m (10 ft lbs).
5. Install exhaust manifold heat shield.
6. Install the exhaust manifold heat shield bolt. Tighten the exhaust manifold heat shield bolts to 14 N.m (10 ft lbs.
7. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Scheme 19

Scheme 20

Scheme 21

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Remove the exhaust manifold heat shield bolts and shield.
3. Remove the cover to the outlet pipe bolt (1) through the exhaust manifold runners.
4. Raise the vehicle.
5. Disconnect the radiator outlet hose (1) from the radiator outlet pipe (3).
6. Remove the radiator outlet pipe (1) to the oil pan (2) bolt (3).
7. Remove right front wheel/tire assembly.
8. Remove right engine splash shield.
9. Remove trans-to-engine brace.
10. Remove the radiator outlet pipe.
11. Remove the thermostat (2).
12. Clean the mating surfaces of the radiator outlet pipe and the coolant pump cover.

1. Install the thermostat (2).
2. Install radiator outlet pipe.
3. Install the radiator outlet pipe (1) to oil pan (2). Tighten the outlet pipe to oil pan bolt to 26 N.m (19 ft lbs).
4. Connect the radiator hose (1) to the outlet pipe (3).
5. Install trans-to-engine brace.
6. Install right engine splash shield.
7. Install right front wheel/tire assembly.
8. Lower the vehicle.
9. Install the outlet pipe bolts (1) through the exhaust manifold runners. Tighten bolts to 14 N.m (10 ft lbs).
10. Install the exhaust manifold heat shield and bolts. Tighten the exhaust manifold heat shield bolts to 14 N.m (10 ft lbs).
11. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
12. Start the engine. After the engine reaches normal operating temperature, check for coolant leaks.

Scheme 22

Scheme 23

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Remove the exhaust manifold. Refer to «EXHAUST MANIFOLD REPLACEMENT (2.4L)»(ref-173560-S29463599222005031700000) .
3. Remove the coolant outlet pipe. Refer to «Radiator Pipe Replacement - Outlet»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Disconnect the heater hose quick connect from the heater outlet pipe.
5. Remove the timing chain and tensioner. Refer to «TIMING CHAIN, SPROCKETS AND/OR TENSIONER REPLACEMENT»(ref-174831-S02259639632005041100000) .
6. Remove the water pump cover-to-cylinder block bolts.
7. Remove water pump cover pipe bracket bolt (Bellhousing bolt).
8. Remove the water pump-to-timing chain housing nuts.
9. Remove the water pump and cover assembly.
10. Remove the water pump cover-to-coolant pump assembly bolts.
11. Clean all sealing surfaces.

Important: Before you install the coolant pump, read the entire procedure. Follow the tightening sequences in order to avoid part damage and to provide proper sealing.

1. Install the water pump cover to the water pump assembly.
2. Install the pump cover bolts. Hand tighten the bolts.
3. Install water pump/cover assembly.
4. Install the cover-to-block bolts. Hand tighten the bolts.
5. Install the coolant pump-to-timing chain housing nuts. Hand tighten the nuts.
6. Install water pump cover pipe bolt (Bellhousing Bolt).
7. Torque in sequence as follows: 7.1. Tighten the pump assembly-to-timing chain housing nuts. Tighten nuts to 26 N.m (19 ft lbs). 7.2. Tighten the pump cover-to-pump assembly bolts. Tighten the bolts to 14 N.m (10 ft lbs). 7.3. Tighten the coolant pump cover-to-engine block bolts. Tighten the bottom bolt first. Tighten bolts to 26 N.m (19 ft lbs).
8. Install heater hose to water pump cooling pipe.
9. Install radiator outlet pipe. Refer to «Radiator Pipe Replacement - Outlet»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system) .
10. Install the exhaust manifold and install new gaskets. Refer to «EXHAUST MANIFOLD REPLACEMENT (2.4L)»(ref-173560-S29463599222005031700000) .
11. Install oil level indicator tube and indicator.
12. Connect the brake vacuum pipe to the cam housing.
13. Raise the vehicle.
14. Install catalytic converter.
15. Install the timing chain and tensioner.
16. Lower the vehicle.
17. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
18. Inspect the system for leaks.

Scheme 24

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Loosen the coolant pump pulley bolts.
3. Remove the accessory drive belt.
4. Remove the coolant pump pulley bolts.
5. Remove the coolant pump pulley.
6. Remove the coolant pump bolts.
7. Remove the coolant pump and the gasket.
8. Completely clean the sealing surfaces of the coolant pump and the engine block.

1. Using a new gasket, install the coolant pump and the attaching bolts. Coat the bolt threads with pipe sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. Tighten the coolant pump bolts to 25 N.m (18 ft lbs).
2. Install the coolant pump pulley and bolts. Tighten the coolant pump pulley bolts to 30 N.m (22 ft lbs).
3. Install the accessory drive belt.
4. Refill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
5. Start the engine. After the engine reaches normal operating temperature, check for coolant leaks.

Water Pump Replacement (2.2L - L61)

Tools Required

J 43651 Water Pump Sprocket Holding Tool

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

1. If equipped with an automatic transmission, remove the exhaust manifold. Refer to «EXHAUST MANIFOLD REMOVAL»(ref-173440-S18803208532005102000000) .
2. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
3. Raise and suitably support the vehicle.
4. Remove the right front tire and wheel.
5. Remove the front fender liner.
6. Remove the access plate on the water pump sprocket from the timing cover.
7. Install J 43651 to the water pump sprocket.
8. Use the access plate bolts to secure J 43651 to the engine front cover.
9. Remove the bolts that secure the sprocket to the water pump.
10. Remove the bolt (1) that secures the engine block to the water pump.
11. Remove the bolt (2) that secures the engine front cover to the water pump.
12. Remove the feed pipe that joins the thermostat housing to the water pump.
13. Remove the 2 bolts that secure the water pump to the engine block.
14. Remove the water pump.

1. Use a threaded stud in the hub to align the hub to the water pump sprocket.
2. Install the water pump.
3. Install the 2 bolts that secure the water pump to the engine block.
4. Install the feed pipe that joins the thermostat housing to the water pump.
5. Install the engine front cover bolt (2) and the bolt (1) that secures the engine block to the water pump. Tighten the bolts to 20 N.m (15 ft lbs).
6. Install 2 of the bolts that secure the water pump sprocket to the water pump.
7. Remove the threaded stud.
8. Install the last bolt. Tighten the bolts to 10 N.m (89 in lbs).
9. Remove J 43651 .
10. Install the access plate on the water pump sprocket to the timing cover.
11. Install the bolts that secure the access plate to the timing cover. Tighten the bolts to 10 N.m (18 in lbs).
12. Install the front fender liner.
13. Install the right front tire and wheel.
14. If equipped with an automatic transmission, install the exhaust manifold.
15. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Engine Coolant Temperature Sensor Replacement

Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

Scheme 30

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Disconnect the engine coolant temperature sensor electrical connector.
3. Carefully remove the engine coolant temperature sensor.

Note. Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.

Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

1. Coat the threads with sealer P/N 9985253 or equivalent.
2. Install the engine coolant temperature sensor. Tighten the sensor to 20 N.m (15 ft lbs).
3. Connect the engine coolant temperature sensor electrical connector.
4. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

1. Turn the drain cock counterclockwise in order to open the drain cock.
2. Pull the stem out of the radiator body.
3. Clean or replace the seal and stem as necessary.

1. Return the stem to the radiator body.
2. Turn the drain clockwise in order to close the drain cock.

Radiator Replacement

Tools Required

J 38185 Hose Clamp Pliers

Scheme 31

Scheme 32

Scheme 33

1. Disable the SIR system. Refer to «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-150706-S21979708732002112000000) .
2. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
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).
6. Raise the vehicle.
7. Disconnect the forward discriminating sensor harness. Refer to «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-150706-S21979708732002112000000) .
8. Remove the cooling fan assembly. Refer to «Cooling Fan Replacement - Electric»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system) .
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.
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.
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.

1. Install the radiator assembly to the vehicle.
2. Install the condenser to the radiator.
3. Use the J 38185 in order to install the surge tank hose to the radiator.
4. Route the forward discriminating sensor harness. Refer to «FRONT END DISCRIMINATING SENSOR»(ref-150706-S11378941422002112000000) .
5. Raise the vehicle.
6. Install the lower transmission oil cooler line to the radiator. Tighten the line to 36 N.m (27 ft lbs).
7. Install the cooling fan assembly. Refer to «Cooling Fan Replacement - Electric»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Use the J 38185 in order to Install the radiator outlet hose to the radiator.
9. Connect the forward discriminating sensor harness connector. Refer to «FRONT END DISCRIMINATING SENSOR»(ref-150706-S11378941422002112000000) .
10. Lower the vehicle.
11. Use the J 38185 in order to Connect the radiator inlet hose to the radiator.
12. Install the upper transmission oil cooler line to the radiator. Tighten the upper transmission oil cooler line to 36 N.m (27 ft lbs).
13. Install the upper radiator mount bolts (1) to the upper tie bar. Tighten the bolts to 10 N.m (89 in lbs).
14. Install the hood latch support.
15. Install the right and the left headlamp assemblies.
16. Install and adjust the hood latch assembly.
17. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
18. Enable the SIR system. Refer to «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-150706-S21979708732002112000000) .

Scheme 34

1. Raise the vehicle.
2. Drill out pop rivets (2) from the lower air deflector (1).
3. Remove the lower air deflector.

1. Install the lower air deflector (1) into position.
2. Install the pop rivets (2) to the lower air deflector.
3. Lower the vehicle.

Scheme 35

Scheme 36

1. Disconnect the coolant heater cord (1).
2. Remove the coolant heater bolt.
3. Remove the coolant heater.

1. Install the coolant heater.
2. Install the coolant heater bolt. Tighten the bolt to 10 N.m (89 in lbs)
3. Connect the coolant heater cord (1).

Scheme 37

Scheme 38

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Disconnect the coolant heater cord.
3. Remove the oil fill tube bolt (2).
4. Remove the oil fill tube (3).
5. Remove the coolant heater (1).

1. Install the coolant heater (1).
2. Install the oil fill tube (3).
3. Install the oil fill tube bolt (2). Tighten the bolt to 50 N.m (37 ft lbs)
4. Connect the coolant heater cord.
5. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Scheme 39

Scheme 40

1. Drain the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .
2. Disconnect the coolant heater cord (2).
3. Remove the coolant heater (2).

1. Install the coolant heater (2). Tighten the coolant heater to 24 N.m (18 ft lbs)
2. Connect the coolant heater cord (2).
3. Fill the cooling system. Refer to «DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)»(/chevrolet/cavalier/iii-1995-2005/remont/cooling-system-mechanical/#engine-cooling-system__draining-filling-cooling-system) .

Scheme 41

1. Disconnect the engine coolant heater cord.
2. Remove the clips from the engine wiring harness and remove the cord (1).

1. Connect the engine coolant heater cord.
2. Install the clips from the engine wiring harness and remove the cord (1).

Scheme 42

1. Disconnect the engine coolant heater cord (1).
2. Remove the clips from the engine mount and surge tank.

1. Install the clips from the engine mount and surge tank.
2. Connect the engine coolant heater cord (1).

Scheme 43

1. Disconnect the engine coolant heater cord (2).
2. Remove the clip from the engine front cover (1).
3. Remove the clips from the engine mount and surge tank.

1. Install the clips from the engine mount and surge tank.
2. Install the clip from the engine front cover (1).
3. Connect the engine coolant heater cord (2).

Scheme 44

Scheme 45

See also:
• Flushing
• DRAINING & FILLING COOLING SYSTEM - 2.2L (L61)
• Radiator Pipe Replacement - Outlet