GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Cavalier 🢒 Engine 🢒 Engine Cooling 🢒 Radiator Outlet Pipe Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

    Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

  1. Disconnect the negative battery cable.
  2. Drain the coolant. Recover the coolant. Refer to Cooling System Draining and Filling .

    3. Object Number: 25787 Size: SH
  3. Remove the exhaust manifold heat shield.
  4. Remove the cover to the outlet pipe bolt (1) through the exhaust manifold runners.
  5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    6. Object Number: 25807 Size: SH
  6. Disconnect the radiator outlet hose (1) from the radiator outlet pipe (3).

    7. Object Number: 25789 Size: SH
  7. Remove the radiator outlet pipe (1) to the oil pan (2) bolt (3).

    8. Object Number: 25784 Size: SH
  8. Remove the cover to the outlet pipe bolt.
  9. Remove the thermostat (2).
  10. Clean the mating surfaces of the radiator outlet pipe and the coolant pump cover.

Installation Procedure

    Object Number: 25784 Size: SH
  1. Install the thermostat (2).

    2. Notice: 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.

  2. Install the cover to the outlet pipe bolt

    3. Tighten
    Tighten the bolt to 14 N·m (124 lb in).


    Object Number: 25789 Size: SH
  3. Install the radiator outlet pipe (1) to oil pan (2).

    4. Tighten
    Tighten the outlet pipe to oil pan bolt to 26 N·m (19 lb ft).


    Object Number: 25807 Size: SH
  4. Connect the radiator hose (1) to the outlet pipe (3).
  5. Lower the vehicle.

    6. Object Number: 25787 Size: SH
  6. Install the cover to the outlet pipe bolt (1) through the exhaust manifold runners.
  7. Install the manifold heat shield.
  8. Fill the cooling system. Refer to Cooling System Draining and Filling .
  9. Connect the negative battery cable.
  10. Inspect for leaks.
  11. Start the engine. After the engine reaches normal operating temperature, check for coolant leaks.