Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.

Install the radiator assembly to the vehicle. See Figure.
Install the condenser to the radiator.
Install condenser to radiator mounting bolts (2).
Use the J 38185 in order to install the surge tank hose to the radiator.

Fig 1: Connecting Surge Tank Hose At Radiator
Courtesy of GENERAL MOTORS CORP.
Route the forward discriminating sensor harness. Refer to ZONE 1 .
Raise the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
Install the lower transmission oil cooler line to the radiator.
Tighten

Tighten the line to 36 N.m (27 lb. ft).

Fig 2: Connecting Transmission Oil Cooler Lines At Radiator
Courtesy of GENERAL MOTORS CORP.
Install the cooling fan assembly. Refer to Cooling Fan Replacement - Electric .
Use the J 38185 in order to install the radiator outlet hose to the radiator.

Fig 3: Connecting Radiator Hoses At Radiator
Courtesy of GENERAL MOTORS CORP.
Connect the forward discriminating sensor harness connector. Refer to ZONE 1 .
Lower the vehicle.
Use the J 38185 in order to connect the radiator inlet hose to the radiator.
Install the upper transmission oil cooler line to the radiator.
Tighten

Tighten the upper transmission oil cooler line to 36 N.m (27 lb. ft).
Install the upper radiator mount bolts (1) to the upper tie bar.

Fig 4: Installing Upper Radiator Mount Bolts
Courtesy of GENERAL MOTORS CORP.

Tighten

Tighten the bolts to 10 N.m (89 lb. in).
Install the hood latch support. Refer to HOOD LATCH SUPPORT REPLACEMENT .
Install the right and the left headlamp assemblies Refer to HEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT (PONTIAC) in Lighting Systems.
Install and adjust the hood latch assembly. Refer to HOOD LATCH REPLACEMENT .
Fill the cooling system. Refer to Draining and Filling Cooling System (L61) .
Enable the SIR system. Refer to ZONE 1 .