In 1997 the Chevy Cavalier with a 2.2 liter engine was still riding high on its popularity due to good gas mileage and affordable price. Consumers looking to buy American, yet ease the strain on their wallets, made the Cavalier a mainstay in the Chevy lineup for 24 years. Replaced by the Cobalt in 2005, the Cavalier was also a favorite of "do-it-yourselfers" because of its simple platform and abundance of affordable aftermarket parts.
Park your vehicle on a solid, level surface. Place wheel chocks behind the rear wheels. Lift the front wheels off the ground by placing a floor jack under the center of the front cross-member. Place jack stands under the solid section of the uni-body -- about 12 inches behind the front wheel well -- on both sides of the vehicle. Lower the vehicle onto the jack stands.
Let the engine cool completely. Remove the coolant reservoir cap. Remove the bolts securing the splash shield under the radiator with a socket and ratchet. Place a drain pan under the radiator drain petcock at the bottom right of the radiator. Loosen the petcock by hand and let the coolant drain into the pan. Tighten the petcock.
Located the thermostat in the housing that is below and behind the alternator on the 2.2 liter engine. It's easy to find by following the lower radiator hose to the housing.
Remove the two thermostat housing bolts with a socket and ratchet. Remove the housing and pull out the thermostat and O-ring. If the O-ring doesn't come off with the thermostat, make sure you remove it from the housing. Wipe the housing mating surfaces clean with a clean rag.
Install the replacement O-ring on the new thermostat -- there is a groove in the O-ring that fits over the flange on the thermostat. Insert the thermostat in the housing and install the housing. Tighten the two housing bolts to 89 inch-pounds with a torque wrench.
Install the splash shield. Lift the vehicle off the jack stands, remove them and lower the vehicle to the ground.
Follow the upper radiator hose to the housing it is connected to. Loosen the bleeder screw on the housing. Pour a 50/50 mixture of DEX-COOL coolant and water into the coolant reservoir until it starts to come out of the bleeder. Tighten the bleeder. Start the engine and let it idle; when the upper radiator hose gets hot, that means the thermostat has opened. Check the coolant level and fill as necessary. Install the coolant reservoir cap.
