How to Install an Engine Coolant Temperature Sensor in a 1996 Cavalier

The engine coolant temperature sensor measures the temperature of the engine coolant and relays that information to the dash-mounted gauge, or on models not equipped with a gauge, the sensor illuminates the warning light when the engine gets too hot. If this sensor fails, it could lead to your engine overheating. Replacing the engine coolant temperature sensor on a 1996 Chevrolet Cavalier can easily be accomplished by the vehicle owner.

Things You'll Need

• Wrench set
• Waste oil collection pan
• Needle-nose pliers
• Socket set
• RTV silicone sealant
• Replacement sensor
• Antifreeze

Instructions

Draining the Cooling System

1. Unhook the negative battery cable from the battery. Loosen the retaining bolt using a wrench. Then pull the clamp off the terminal.

2. Unscrew the radiator cap from the radiator. Press down on the cap with your hand and rotate it counterclockwise. Then lift the cap off the radiator.

3. Locate the petcock valve on the lower right corner of the radiator and place a waste oil collection pan underneath it.

4. Open the petcock valve by turning it counterclockwise with needle-nose pliers.

5. Allow the cooling system to drain fully. Close the petcock valve by turning it clockwise with needle-nose pliers.

Replacing the Engine Coolant Temperature Sensor

1. Locate the thermostat housing. It will be located between the upper radiator hose and the engine.

2. Locate the engine coolant temperature sensor. It will be screwed into the thermostat.

3. Separate the wiring harness from the engine coolant temperature sensor, by pulling the plastic wiring connector off the sensor by hand.

4. Unscrew the engine coolant temperature sensor from the thermostat using a socket.

5. Coat the threads on the new sensor with RTV silicone. Do not put sealant anywhere besides the threads of the sensor.

6. Screw the new sensor into the thermostat housing, using a socket.

Refilling the Cooling System

1. Refill the radiator with a 50/50 mix of antifreeze and water.

2. Reconnect the ground cable to the negative battery terminal. Slide the clamp over the terminal. Then tighten the retaining bolt with a wrench.

3. Start the engine and allow it to run with the radiator cap off for three to five minutes. This will bleed air from the cooling system.

4. Shut the engine off.

5. Screw the radiator cap onto the radiator.

Tips & Warnings

• If you have changed the engine coolant recently, you can drain the antifreeze to a level below the thermostat housing.

• The scent of antifreeze is highly attractive to household pets. It is also highly toxic. Keep small children and pets away from antifreeze.

References

• "Chilton's General Motors Cavalier/Skyhawk/Sunbird/Sunfire 1982-96 Repair Manual;" Chilton Book Company; 1996
• “Haynes General Motors Chevrolet Cavalier & Pontiac Sunfire: 1995 through 2004 Repair Manual;” John Haynes; 2005

Resources

• Club Cav