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Home › Pontiac › 2005 › G6 Base › Repair and Diagnosis › Engine Mechanical › Cooling System (Mechanical) › Engine Cooling System › Repair Instructions › Radiator Replacement › Installation Procedure

Installation Procedure

  1. Install the cooling fan and shroud assembly to the radiator.
    Fig 1: Snapping Fan Shroud Tabs Into Radiator Clips
    GM1212433Courtesy of GENERAL MOTORS CORP.
  2. Snap the fan shroud tabs into the radiator clips.
  3. Install the transmission oil cooler pipes to the radiator. Refer to Transmission Fluid Cooler Line Quick Connect Fitting in Automatic Transaxle - 4T40-E/4T45-E.
    4. Fig 2: View Of Radiator, Cooling Fan Shroud And Transmission Oil Cooler Pipe Assembly
    GM1202423Courtesy of GENERAL MOTORS CORP.
  4. Install the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
    5. Fig 3: View Of Radiator Air Side Seals
    GM1336545Courtesy of GENERAL MOTORS CORP.
  5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
    6. NOTE: The bolt retaining the condenser to the radiator end tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.
    IMPORTANT: Replace the condenser mounting bolts and nuts.
    Fig 4: Pushing Upward On Radiator And Downward On Condenser
    GM1201922Courtesy of GENERAL MOTORS CORP.
  6. Install the condenser mounting nuts to the radiator.
  7. Insert the condenser mounting tabs into the radiator clips.
    8. NOTE: Refer to Fastener Notice in Cautions and Notices.
    Fig 5: View Of Radiator Lower Mounts
    GM1203511Courtesy of GENERAL MOTORS CORP.
  8. Install the condenser to the radiator bolts.

    Tighten:  Tighten the bolts to 6 N.m (53 lb in).

    9. Fig 6: Bending Radiator Air Side Seals
    GM1336474Courtesy of GENERAL MOTORS CORP.
  9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
    10. Fig 7: Inspecting Radiator Air Side Seals
    GM1337348Courtesy of GENERAL MOTORS CORP.
  10. The radiator air side seals must be in the proper position for proper air flow.
    11. IMPORTANT: Replace the radiator lower mounts as a pair or vibration may result.
  11. Install the radiator lower mounts.
    12. Fig 8: View Of Lower Radiator Support Bracket Bolts
    GM1203468Courtesy of GENERAL MOTORS CORP.
  12. Install the lower radiator support brackets.
  13. Install the lower radiator support bracket bolts.

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

  14. Install the transmission oil cooler pipes to the transmission.
    Fig 9: View Of Both Transmission Oil Cooler Pipes From Transmission
    GM1203519Courtesy of GENERAL MOTORS CORP.
  15. Install the transmission oil cooler pipes attachment nut to the transmission.

    Tighten:  Tighten the nut to 7 N.m (62 lb in).

  16. Install the radiator outlet hose to the radiator.
    Fig 10: Radiator Outlet Hose At Engine (3.5L)
    GM1203449Courtesy of GENERAL MOTORS CORP.
  17. Reposition the radiator outlet hose clamp at the radiator using the J 38185  . See Special Tools .
    18. Fig 11: View Of Left Radiator Air Deflector Retainers
    GM1203535Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.
  18. Install the left radiator air deflector.
  19. Install the left radiator air deflector retainers.
    20. Fig 12: View Of Right Front Fender Liner & Retainers
    GM1203530Courtesy of GENERAL MOTORS CORP.
  20. Install the right radiator air deflector.
  21. Install the right radiator air deflector retainers.
  22. Install the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
    23. Fig 13: View Of Lower Radiator Air Deflector And Retainers
    GM1203537Courtesy of GENERAL MOTORS CORP.
  23. Install the lower radiator air deflector.
  24. Install the lower radiator air deflector retainers.
  25. Lower the vehicle.
  26. Install the radiator inlet hose to the radiator.
    Fig 14: Radiator Inlet Hose At Radiator (3.5L)
    GM1203452Courtesy of GENERAL MOTORS CORP.
  27. Reposition the radiator inlet hose clamp at the radiator using the J 38185  . See Special Tools .
  28. Install the surge tank outlet hose to the radiator.
    Fig 15: View Of Surge Tank Outlet Hose At Radiator
    GM1215548Courtesy of GENERAL MOTORS CORP.
  29. Reposition the surge tank outlet hose clamp at the radiator using theJ 38185  . See Special Tools .
  30. Remove the rope attached to the condenser and upper tie bar.
    31. Fig 16: View Of Upper Radiator Support Brackets
    GM1202411Courtesy of GENERAL MOTORS CORP.
  31. Install the upper radiator support brackets.
    32. IMPORTANT: Do not allow the upper bracket to twist when tightening the screw or vibration may result.
    Fig 17: View Of Upper Radiator Support Bracket Bolts
    GM1212430Courtesy of GENERAL MOTORS CORP.
  32. Install the upper radiator support bracket bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

  33. Install the right headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement in Lighting Systems.
  34. Install the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement in Lighting Systems.
  35. Fill the coolant. Refer to Draining and Filling Cooling System .
  36. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in Automatic Transaxle - 4T40-E/4T45-E.
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