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Removal And Installation: Radiator: Installation

WARNING: This page is about a different car, the 2002 Saturn LW300 and 2002 Saturn L300. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install upper radiator to condenser gasket on radiator.
    Fig 1: Installing Upper Radiator-To-Condenser Gasket
    G01036626Courtesy of GENERAL MOTORS CORP.
  2. Install radiator lower mounting pins into rubber mounts.
    Fig 2: Installing Radiator Lower Mounting Pins Into Rubber Mounts
    G01036627Courtesy of GENERAL MOTORS CORP.
  3. Install radiator degas hose to radiator end tank and position clamp at 1 o'clock.
    Fig 3: Installing Degas Hose To Radiator End Tank
    G01036628Courtesy of GENERAL MOTORS CORP.
  4. Position upper radiator mounts over upper pins and install radiator bracket to rail bolts.

    Torque: 

    Radiator Bracket-to-Rail Bolts: 6 N.m (53 in-lbs) 

    Fig 4: Installing Upper Radiator Mounts
    G01036629Courtesy of GENERAL MOTORS CORP.
  5. Position condenser tabs under radiator tabs and install condenser to radiator bolts.

    Torque: 

    Condenser-to-Radiator Bolts: 4 N.m (35 in-lbs) 

    Fig 5: Positioning Condenser Under Radiator Tabs
    G01036630Courtesy of GENERAL MOTORS CORP.
  6. Install lower radiator to condenser gasket.
    Fig 6: Installing Lower Radiator-To-Condenser Gasket
    G01036631Courtesy of GENERAL MOTORS CORP.
  7. Install condenser block to radiator end tank bolt.

    Torque: 

    Condenser Block-to-Radiator End Tank Bolt: 4 N.m (35 in-lbs) 

    Fig 7: Installing Condenser Block-To-Radiator End Tank Bolt
    G01036632Courtesy of GENERAL MOTORS CORP.
  8. Remove condenser support wire or plastic tie.
  9. Remove cap and install lower transaxle cooler line to radiator end tank.

    Torque: 

    Lower Transaxle Cooler Line-to-Radiator End Tank: 4 N.m (35 in-lbs) 

    Fig 8: Installing Lower Transaxle Cooler Line To Radiator End Tank
    G01036633Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  White line on hose should be installed at 12 o'clock position.

  10. Install lower radiator hose to radiator fitting.
  11. Install clamp at 11 o'clock position.
    Fig 9: Installing Lower Radiator Hose
    G01036634Courtesy of GENERAL MOTORS CORP.
  12. Install forward wiring harness into forward rail clips.
    Fig 10: Installing Forward Wiring Harness
    G01036635Courtesy of GENERAL MOTORS CORP.
  13. Install fan and shroud assembly onto radiator lower tabs.
    Fig 11: Installing Fan & Shroud Onto Radiator Tabs
    G01036636Courtesy of GENERAL MOTORS CORP.
    NOTE: Verify that the pusher fan electrical harness is not between the fan shroud and the radiator.
  14. Install fan shroud to radiator bolts.

    Torque: 

    Fan Shroud-to-Radiator Bolts: 4 N.m (35 in-lbs) 

    Fig 12: Installing Fan Shroud-To-Radiator Bolts
    G01036637Courtesy of GENERAL MOTORS CORP.
  15. Install upper transaxle oil cooler line into radiator end tank retainer.
  16. Remove cap and install upper transaxle oil cooler line to radiator end tank.

    Torque: 

    Upper Transaxle Cooler Line-to-Radiator End Tank: 25 N.m (18 ft-lbs) 

    Fig 13: Installing Upper Transaxle Cooler Line To Radiator End Tank
    G01036638Courtesy of GENERAL MOTORS CORP.
  17. Route pusher fan electrical harness around outside of radiator end tank to upper fan shroud.
  18. Install fan electrical connectors into connector retainers as shown.
  19. Connect both fan electrical connectors.
    Fig 14: Connecting Fan Electrical Connectors
    G01036639Courtesy of GENERAL MOTORS CORP.
  20. Install pusher fan harness under routing tabs on fan shroud.
  21. Install upper radiator hose to radiator end tank and position clamp at 12 o'clock position.
    Fig 15: Installing Upper Radiator Hose
    G01036640Courtesy of GENERAL MOTORS CORP.
  22. Install power steering fluid reservoir to fan shroud bolts.

    Torque: 

    Power Steering Fluid Reservoir-to-Fan Shroud Bolts: 5 N.m (44 in-lbs) 

    Fig 16: Installing Power Steering Fluid Reservoir
    G01036641Courtesy of GENERAL MOTORS CORP.
  23. Verify battery tray is clean.
  24. Install battery.
  25. Install battery hold down/fan control module bracket.

    Torque: 

    Battery Hold-Down Bracket: 20 N.m (15 ft-lbs) 

    Fig 17: Installing Fan Control Module Bracket
    G01036642Courtesy of GENERAL MOTORS CORP.
    NOTE: Battery life is reduced if battery insulating cover is not used.
  26. Install battery insulating cover.
    Fig 18: Installing Battery Insulating Cover
    G01036643Courtesy of GENERAL MOTORS CORP.
  27. Install fan control module by sliding down onto bracket.
    Fig 19: Installing Fan Control Module Onto Bracket
    G01036644Courtesy of GENERAL MOTORS CORP.
  28. Connect positive battery cable.

    Torque: 

    Battery Terminal Bolts: 17 N.m (13 ft-lbs) 

  29. Connect negative battery cable.

    Torque: 

    Battery Terminal Bolts: 17 N.m (13 ft-lbs) 

  30. Fill cooling system. Refer to COOLANT REPLACEMENT .
  31. Use fresh water to rinse away any coolant that was spilled during service.
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