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Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Grand Am and 2004 Oldsmobile Alero. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Electric Cooling Fan Mounting View
    GM1364791Courtesy of GENERAL MOTORS CORP.
  1. Install the fan shroud to the radiator.
  2. Install the condenser to the radiator.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the condenser to radiator bolts.

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

    4. Fig 2: ViewOf Radiator, Fan, And Condenser
    GM181871Courtesy of GENERAL MOTORS CORP.
  4. Install the radiator, fan, and condenser as an assembly to the vehicle.
    5. Fig 3: Lower Radiator Support Mounting Panel
    GM486715Courtesy of GENERAL MOTORS CORP.
  5. Install the lower radiator support mounting panel.

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

    6. Fig 4: View Of Evaporator Hose Assembly At Condenser
    GM590055Courtesy of GENERAL MOTORS CORP.
  6. Remove the cap or tape from the evaporator hose.
  7. Install a new seal washer on the condenser end of the evaporator hose assembly. Refer to Sealing Washer Replacement .
  8. Install the evaporator hose to the condenser outlet.
  9. Install the condenser outlet to the evaporator line bolt.

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

    10. Fig 5: Transaxle Oil Cooler Pipes
    GM161040Courtesy of GENERAL MOTORS CORP.
  10. Install the lower transaxle cooler line fitting.

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

    11. Fig 6: Coolant Fan Connector Locations
    GM1366085Courtesy of GENERAL MOTORS CORP.
  11. Install the cooling fan electrical connectors.
  12. Install the lower closeout panel.
  13. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    14. Fig 7: Identifying Radiator Hoses & Related ComponentsClamps
    GM1310291Courtesy of GENERAL MOTORS CORP.
  14. Install the surge tank outlet/radiator outlet hose (6) to the radiator.
  15. Use the J 38185  in order to reposition the surge tank outlet/radiator outlet hose clamp (7) to the radiator. See Special Tools and Equipment .
  16. Install the surge tank outlet/radiator outlet hose (6) to the surge tank.
  17. Use the J 38185  in order to reposition the surge tank outlet/radiator outlet hose clamp (4) to the surge tank. See Special Tools and Equipment .
  18. Install the radiator inlet hose (2) to the radiator.
  19. Use the J 38185  in order to reposition the radiator inlet hose clamp (1) to the radiator. See Special Tools and Equipment .
    20. Fig 8: View Of High Side Hose To Condenser Fitting
    GM588318Courtesy of GENERAL MOTORS CORP.
  20. Remove the cap or tape from the discharge hose.
  21. Install a new sealing washer to the discharge hose. Refer to Sealing Washer Replacement in Heating, Ventilation and Air Conditioning.
  22. Install the condenser inlet fitting to the discharge hose.

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

    23. Fig 9: View Of A/C High Pressure Switch Connector
    GM588312Courtesy of GENERAL MOTORS CORP.
  23. Install the refrigerant pressure sensor electrical connector.
    24. Fig 10: Transaxle Oil Cooler Pipes
    GM161040Courtesy of GENERAL MOTORS CORP.
  24. Install the upper transaxle oil cooler line fitting.

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

  25. Refill the cooling system. Refer to Draining and Filling Cooling System (LA1)  or Draining and Filling Cooling System (L61) .
  26. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
  27. Leak test the fittings of the reinstalled components using the J 39400-A  . See Special Tools and Equipment .
  28. Install the battery tray.
  29. Install the battery. Refer to Battery Replacement in Engine Electrical.
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