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Home >> Pontiac >> 2005 >> Sunfire Standard >> Repair and Diagnosis >> Engine Mechanical >> Cooling System (Mechanical) >> Engine Cooling System >> Repair Instructions >> Radiator Replacement >> Installation Procedure

Installation Procedure

    Fig 1: Identifying Radiator Condenser
    GM25811Courtesy of GENERAL MOTORS CORP.
  1. Install the radiator assembly to the vehicle.
  2. Install the condenser to the radiator.
  3. Install condenser to radiator mounting bolts (2).
    4. Fig 2: Identifying Radiator Vent & Outlet Hoses
    GM1195908Courtesy of GENERAL MOTORS CORP.
  4. Use theJ 38185  in order to install the surge tank hose (3) to the radiator. See Special Tools .
  5. Route the forward discriminating sensor harness. Refer to SIR Disabling and Enabling Zone 1 in SIR.
  6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    7. Fig 3: Locating Lower Transmission Oil Cooler Line
    GM12063Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Install the lower transmission oil cooler line to the radiator.

    Tighten:  Tighten the line to 36 N.m (27 lb ft).

  8. Install the cooling fan assembly. Refer to Cooling Fan Replacement - Electric .
  9. Install the radiator outlet hose (6) to the radiator.
    10. Fig 4: View Of Surge Tank Components
    GM1172693Courtesy of GENERAL MOTORS CORP.
  10. Use theJ 38185  in order to reposition the radiator outlet hose clamp (7). See Special Tools .
  11. Connect the forward discriminating sensor harness connector. Refer to SIR Disabling and Enabling Zone 1 in SIR.
  12. Lower the vehicle.
  13. Install the radiator inlet hose (2) to the radiator.
  14. Use theJ 38185  in order to reposition the radiator inlet hose clamp (1). See Special Tools .
    15. Fig 5: Locating Lower Transmission Oil Cooler Line
    GM12063Courtesy of GENERAL MOTORS CORP.
  15. Install the upper transmission oil cooler line to the radiator.

    Tighten:  Tighten the upper transmission oil cooler line to 36 N.m (27 lb ft).

    16. Fig 6: Locating Upper Radiator Mount Bolts
    GM25877Courtesy of GENERAL MOTORS CORP.
  16. Install the upper radiator mount bolts (1) to the upper tie bar.

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

  17. Install the hood latch support. Refer to Hood Latch Support Replacement in Body Front End.
  18. Install the right and the left headlamp assemblies. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Pontiac) in Lighting Systems.
  19. Install and adjust the hood latch assembly. Refer to Hood Latch Replacement in Body Front End.
  20. Fill the cooling system. Refer to Draining and Filling Cooling System (L61) .
  21. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1 in SIR.
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