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Home › Saturn › 2004 › Ion Red Line › Repair and Diagnosis › Engine Mechanical › Cooling System (Mechanical) › Engine Cooling System › Repair Instructions › Radiator Replacement › Installation Procedure

Installation Procedure

  1. Verify that the upper radiator mounts are installed in the vehicle.
    2. Fig 1: View Of Upper Radiator Mounts
    GM873610Courtesy of GENERAL MOTORS CORP.
  2. Install the upper radiator air baffle.
    3. Fig 2: View Of Upper Radiator Air Baffle
    GM877652Courtesy of GENERAL MOTORS CORP.
  3. Tilt the condenser forward in the vehicle. Tilt the cooling fan assembly rearward in the vehicle. Install the radiator assembly into the vehicle.
    4. Fig 3: Tilting Condenser
    GM877649Courtesy of GENERAL MOTORS CORP.
  4. Verify that the upper radiator mount pins align with the upper radiator mounts.
    5. Fig 4: Aligning Upper Radiator Mount Pins With Upper Radiator Mounts
    GM873609Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the lower radiator mounts, brackets, and bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    6. Fig 5: View Of Lower Radiator Mount, Brackets And Bolts
    GM877644Courtesy of GENERAL MOTORS CORP.
  6. Install the right engine splash shield to radiator mount push-in retainer.
  7. If equipped with a manual transmission, install the left engine splash shield to radiator mount push-in retainer.
    8. Fig 6: View Of Left Engine Splash Shield-To-Radiator Mount Push-In Retainer
    GM899628Courtesy of GENERAL MOTORS CORP.
  8. If equipped with air conditioning, install the right and left radiator side baffles.
    9. Fig 7: View Of Right & Left Radiator Side Baffles
    GM877650Courtesy of GENERAL MOTORS CORP.
  9. Slide the condenser up to engage the upper mounting tabs into the radiator.
    10. Fig 8: Locating Radiator Upper Mounting Tabs
    GM877659Courtesy of GENERAL MOTORS CORP.
  10. Install the condenser bolts.

    Tighten:  Tighten the bolts to 10 N.m (88 lb in).

    11. Fig 9: Locating Condenser Bolts
    GM877658Courtesy of GENERAL MOTORS CORP.
  11. Install the air dam and push-in retainers.
    12. Fig 10: View Of Air Dam And Push-In Retainers
    GM851691Courtesy of GENERAL MOTORS CORP.
  12. Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the fan shroud onto the radiator.
    13. Fig 11: View Of Cooling Fan Assembly-To-Radiator Connectors
    GM877645Courtesy of GENERAL MOTORS CORP.
  13. If equipped with an automatic or VTi transmission, install the lower transmission oil cooler line and seal the radiator.

    Tighten:  Tighten the transmission oil cooler line to 20 N.m (15 lb ft).

    14. Fig 12: View Of Lower Transmission Oil Cooler Line
    GM875752Courtesy of GENERAL MOTORS CORP.
  14. If equipped with an automatic or VTi transmission, install the left engine splash shield. Refer to Splash Shield Replacement - Engine in Body Front End.
    15. Fig 13: View Of Left Engine Splash Shield
    GM851688Courtesy of GENERAL MOTORS CORP.
  15. If equipped with an automatic or VTi transmission, install the left front wheelhouse liner. Refer to Front Fender Liner Replacement in Body Front End.
    16. Fig 14: View Of Left Front Wheelhouse Liner
    GM864091Courtesy of GENERAL MOTORS CORP.
  16. Lower the vehicle.
  17. If equipped with an automatic or VTi transmission, install the upper transmission oil cooler line and seal to the radiator.

    Tighten:  Tighten the transmission oil cooler line to 20 N.m (15 lb ft).

    18. Fig 15: View Of Upper Transmission Oil Cooler Line
    GM873611Courtesy of GENERAL MOTORS CORP.
  18. Install the radiator outlet hose to the radiator.
    19. Fig 16: View Of Radiator Outlet Hose & Radiator - 2.2L
    GM873616Courtesy of GENERAL MOTORS CORP.
  19. Reposition the hose clamp to secure the hose using SA9111E  . See Special Tools and Equipment .
  20. Install the radiator inlet hose to the radiator.
    21. Fig 17: View Of Radiator Inlet Hose & Radiator - 2.2L
    GM873615Courtesy of GENERAL MOTORS CORP.
  21. Reposition the hose clamp to secure the hose using SA9111E  . See Special Tools and Equipment .
  22. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls-2.2L (L61).
  23. Fill the cooling system. Refer to Draining and Filling Cooling System (2.2L (L61))  or Draining and Filling Cooling System (2.0L (LSJ)) .
    24. IMPORTANT: Do not use ATF P/N 21005966 or P/N 21019223, these fluids are not compatible with these transmissions. Use Saturn P/N 22689186 for the AF23-5 and 22688912 for the VT25-E.
  24. If equipped with an automatic or VTi transmission, add fluid to the transmission as necessary. Refer to Transmission Fluid Checking Procedure in Automatic Transaxle - AF23-5 or to Transmission Fluid Checking Procedure in Automatic Transmission - VT25-E.
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