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How to replace thermostat on 2004 Chevrolet cavalier ?

Locate the thermostat housing. If you're not sure, look where the radiator hose connects to the intake manifold of the Cavalier. The part that the hose connects to is the thermostat housing.

Removal & Installation



2.2L (VIN 4) Engine



  1. Drain the cooling system.
  2. Remove the lower radiator hose from thermostat outlet.

    Click image to see an enlarged view

    Fig. Remove the thermostat outlet bolts and outlet

  3. Remove the thermostat outlet bolts and outlet.

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    Fig. Remove the thermostat

  4. Remove the thermostat.
  5. Clean the mating surfaces of the radiator outlet and the radiator outlet pipe.

To install:

  1. Install the thermostat.
  2. Install the thermostat outlet and bolts.
    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.

  3. Install the coolant outlet attaching bolts and tighten the thermostat outlet bolts to 10 ft. lbs. (14 Nm).
  4. Install the lower radiator hose to thermostat outlet.
  5. Fill the cooling system.
  6. Inspect for leaks.

2.2L (VIN F) Engine



  1. If equipped with an automatic transmission, remove the exhaust manifold.
  2. Drain the cooling system.
  3. Remove the thermostat housing to water pump feed pipe bolts.
  4. Remove the thermostat housing to water pump feed pipe.

    Click image to see an enlarged view

    Fig. Remove the thermostat

  5. Remove the thermostat.

To install:

  1. Install the thermostat.
  2. Install the thermostat housing to water pump feed pipe.

    Click image to see an enlarged view

    Fig. Install the thermostat housing to water pump feed pipe

  3. Install the thermostat housing to water pump feed pipe bolt and tighten the thermostat housing to water pump feed pipe bolt to 89 lb inches (10 Nm).
  4. If equipped with an automatic transmission, install the exhaust manifold.
  5. Fill the cooling system.


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