The 2002 Pontiac Sunfire was a kin to the Chevrolet Cavalier. The 2002 Sunfire was equipped with either a 2.2-liter in-line four-cylinder engine, or a 2.4-liter in-line four-cylinder variant, depending on the trim level of the car. The 2002 Sunfire was available in both two-door and four-door models. The cooling fan on the 2002 Sunfire is electronically controlled, and is mounted to the back of the radiator. The cooling fan pushes air through the fins in the radiator to aide in the cooling of the engine coolant as it passes through the radiator.
Instructions
- 1
Raise the hood of the Sunfire and disconnect the negative battery cable, using an open-end wrench. Raise the front of the Sunfire with a jack. Place jack stands beneath the two front sub-frame rails, then lower the car onto the jack stands.
2Remove the screws and bolts from the plastic hood shut-out panel, using a ratchet and socket. The shut-out panel is the plastic panel located just above the grille area, on top of the radiator core support. Remove the plastic shut-out panel from the engine compartment completely.
3Remove the upper and lower hood latch bolts with a ratchet and socket. Remove the hood latch assembly from the radiator core support. Remove the upper radiator mounting bolts with a ratchet and socket.
4Lay beneath the front bumper of the Sunfire, and position yourself to access the lower radiator fan mounting bolt. Remove the mounting bolt with a ratchet and socket. Slide out from beneath the car. Disconnect the electrical connector from behind the cooling fan, by hand. Remove the engine cooling fan by pushing it horizontally rearward off the radiator, then pulling it straight up and out of the engine compartment.
5Install the new cooling fan onto the rear of the radiator. Connect the electrical connector to the new fan assembly, by hand. Lay beneath the front bumper of the car and insert the lower cooling fan mounting bolt, by hand. Tighten the bolt to 53 inch-pounds with a 3/8-inch-drive torque wrench and socket. Remove yourself from beneath the car.
6Install the hood latch and mounting bolts to the radiator core support. Tighten the lower latch mounting bolts to 20 foot-pounds with a 1/2-inch-drive torque wrench and socket. Tighten the upper mounting bolts to 80 inch-pounds with a 3/8-inch-drive torque wrench and socket. Install the upper radiator-mounting bolts and tighten them to 89 inch-pounds with the 3/8-inch-drive torque wrench.
7Install the plastic filler panel back on top of the radiator core support. Install and tighten all of the screws and bolts snug, using a ratchet and socket. Do not over-tighten the bolts, so that you do not crack the plastic panel. Install the negative battery cable onto the battery, and tighten it snug with an open-end wrench.
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