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Home >> Chevrolet >> 2003 >> Malibu Base >> Repair and Diagnosis >> Engine Mechanical >> Cooling System (Mechanical) >> Engine Cooling System >> Repair Instructions >> Radiator Replacement >> Installation Procedure

Installation Procedure

  1. Install the fan shroud to the radiator.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
    Fig 1: Installing Radiator, Fan, & Condenser As Assembly
    G01514391Courtesy of GENERAL MOTORS CORP.
  2. Install the condenser to radiator bolts.

    Tighten 

    Tighten the bolts to 5 N.m (44 lb in).

  3. Install the radiator, fan, and condenser as an assembly to the vehicle.
  4. Install the lower radiator mounting panel.

    Tighten 

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

  5. Install the condenser outlet to the evaporator line bolt.

    Tighten 

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

  6. Use the J 38185  in order to reposition the lower radiator hose and clamps to the radiator.
  7. Install the lower radiator hose to the radiator.
  8. Install the lower closeout panel.
  9. Lower the vehicle.
  10. Install the cooling fan electrical connection.
  11. Install the lower transaxle oil cooler line.

    Tighten 

    Tighten the fitting to 30 N.m (22 lb ft).

  12. Install the condenser inlet fitting to the discharge hose.

    Tighten 

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

  13. Install the coolant surge tank hose.
  14. Install the upper transaxle oil cooler line fitting.

    Tighten 

    Tighten the fitting to 30 N.m (22 lb ft).

  15. Use the J 38185  in order to reposition the upper radiator hose and clamps.
  16. Install the upper radiator hose.
  17. Refill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM  .
  18. Recharge the A/C system. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation, and Air Conditioning.
  19. Install the battery tray.
  20. Install the battery. Refer to BATTERY REPLACEMENT in Engine Electrical.