SMU - SECTION 6B - REVISED RADIATOR REMOVE/INSTALL PROC.. Chevrolet Cavalier 1996

REVISION: 10/25/96

THIS BULLETIN IS BEING REVISED TO ADD WARRANTY INFORMATION.

SUBJECT: SERVICE MANUAL UPDATE - SECTION 6B - REVISED RADIATOR REMOVE/INSTALL PROCEDURE

MODELS: 1995-97 CHEVROLET CAVALIER 1995-97 PONTIAC SUNFIRE 1996-97 TOYOTA CAVALIER

THIS BULLETIN IS BEING ISSUED TO REVISE THE RADIATOR REMOVE/INSTALL PROCEDURE FOUND IN SECTION 6B OF THE SERVICE MANUAL.

PROCEDURE:

REMOVE OR DISCONNECT

1. NEGATIVE BATTERY CABLE.

2. DISABLE SIR. REFER TO SUPPLEMENTAL INFLATABLE RESTRAINT SECTION OF THE SERVICE MANUAL.

3. DRAIN AND RECOVER THE ENGINE COOLANT. REFER TO "DRAINING" IN COOLING AND RADIATOR SECTION OF THE SERVICE MANUAL.

4. HOOD LATCH FROM MOUNTING PLATE.

5. RIGHT AND LEFT HEADLAMP ASSEMBLIES (INCLUDING CLOSEOUT PANEL).

6. RADIATOR MOUNTS.

7. RAISE VEHICLE.

8. DISCONNECT FORWARD SIR SENSOR HARNESS.

9. COOLING FAN ASSEMBLY.

10. LOWER RADIATOR HOSE FROM RADIATOR.

11. LOWER TRANSMISSION OIL COOLER LINE FROM RADIATOR.

12. LOWER VEHICLE.

13. HOOD LATCH SUPPORT BRACKET AND FORWARD SENSOR W/HARNESS.

14. UPPER TRANSMISSION OIL COOLER LINE FROM RADIATOR.

15. UPPER RADIATOR HOSE FROM RADIATOR (INCLUDING OVERFLOW HOSE).

16. CONDENSER FROM RADIATOR, IF EQUIPPED. DO NOT DISCHARGE A/C SYSTEM.

17. RADIATOR FROM VEHICLE.

INSTALL OR CONNECT

1. RADIATOR TO VEHICLE.

2. CONDENSER TO RADIATOR, IF EQUIPPED.

3. UPPER RADIATOR HOSE TO RADIATOR (INCLUDING OVERFLOW HOSE).

4. UPPER TRANSMISSION OIL COOLER LINE TO RADIATOR.

5. HOOD LATCH SUPPORT BRACKET AND FORWARD SENSOR W/HARNESS.

6. RAISE VEHICLE.

7. LOWER TRANSMISSION OIL COOLER LINE TO RADIATOR.

8. LOWER RADIATOR HOSE TO RADIATOR.

9. COOLING FAN ASSEMBLY.

10. CONNECT FORWARD SIR SENSOR HARNESS.

11. LOWER VEHICLE.

12. RADIATOR MOUNTS.

13. RIGHT AND LEFT HEADLAMP ASSEMBLIES (INCLUDING CLOSEOUT PANEL).

14. HOOD LATCH TO MOUNTING PLATE.

15. REFILL THE ENGINE COOLANT. REFER TO "FILLING" IN COOLING AND RADIATOR SECTION OF THE SERVICE MANUAL.

16. ENABLE SIR. REFER TO SUPPLEMENTAL INFLATABLE RESTRAINT SECTION OF THE SERVICE MANUAL.

17. NEGATIVE BATTERY CABLE.

INSPECT FOR LEAKS.

WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OPERATION LABOR NUMBER DESCRIPTION OPERATION TIME =============== =========== ==============

J3080 RADIATOR - R & R 1.1 HR

J3100 RADIATOR - REPLACE 1.1 HR

ADD: WITH AUTOMATIC TRANSMISSION 0.1 HR

ADD: WITH AIR CONDITIONING 0.1 HR

FIGURES: 00 ATTACHMENTS: 00

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.