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Installation Procedure

WARNING: This page is about a different car, the 2005 Chevrolet Malibu. However, it is still accessible from the selected car via links, so may be relevant.
  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: Removing Radiator, Cooling Fan Shroud And Transmission Oil Cooler Pipe Assembly
    GM1202420Courtesy of GENERAL MOTORS CORP.
  4. Install the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
    5. Fig 3: Removing 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: Removing Radiator Lower Mounts
    GM1203511Courtesy of GENERAL MOTORS CORP.
  8. Install the condenser mounting 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. Fig 10: Removing Left Radiator Air Deflector Retainers
    GM1203536Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.
  16. Install the left radiator air deflector.
  17. Install the left radiator air deflector retainers.
    18. Fig 11: View Of Right Radiator Air Deflector
    GM1203534Courtesy of GENERAL MOTORS CORP.
  18. Install the right radiator air deflector.
  19. Install the right radiator air deflector retainers.
  20. Install the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
    21. Fig 12: View Of Lower Radiator Air Deflector And Retainers
    GM1203537Courtesy of GENERAL MOTORS CORP.
  21. Install the lower radiator air deflector.
  22. Install the lower radiator air deflector retainers.
  23. Lower the vehicle.
  24. Install the radiator inlet hose to the radiator.
    Fig 13: Radiator Inlet Hose At Radiator (2.2)
    GM1203453Courtesy of GENERAL MOTORS CORP.
  25. Reposition the radiator inlet hose clamp at the radiator using the J 38185  . See Special Tools .
  26. Install the radiator outlet hose to the radiator.
    Fig 14: Radiator Outlet Hose At Radiator (2.2L)
    GM1203448Courtesy of GENERAL MOTORS CORP.
  27. Reposition the radiator outlet hose clamp at the radiator using the J 38185  . See Special Tools .
  28. Remove the rope attached to the condenser and upper tie bar.
    29. Fig 15: View Of Upper Radiator Support Brackets
    GM1202411Courtesy of GENERAL MOTORS CORP.
  29. Install the upper radiator support brackets.
    30. IMPORTANT: Do not allow the upper bracket to twist when tightening the screw or vibration may result.
    Fig 16: Installing Upper Radiator Support Bracket Bolts
    GM1212430Courtesy of GENERAL MOTORS CORP.
  30. Install the upper radiator support bracket bolts.

    Tighten:  Tighten the bolts to 10 N.m (7 lb ft).

  31. Install the right headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement in Lighting Systems.
  32. Install the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement in Lighting Systems.
  33. Fill the coolant. Refer to Draining and Filling Cooling System (L61)  or Draining and Filling Cooling System (LX9) .
  34. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in Automatic Transaxle - 4T40-E/4T45-E.
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