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Home >> Saturn >> 2003 >> L200 Standard >> Repair and Diagnosis >> Engine Mechanical >> Cooling System (Mechanical) >> Engine Cooling >> Repair Instructions >> Radiator Replacement (L61) >> Installation Procedure

Installation Procedure

    Fig 1: Removing & Installing Condenser & Pusher Fan Assembly From Radiator
    GM894019Courtesy of GENERAL MOTORS CORP.
  1. Install the gasket between the upper radiator and the condenser.
    2. Fig 2: Installing Radiator Lower Mounting Pins To Rubber Mounts
    GM894720Courtesy of GENERAL MOTORS CORP.
  2. Install the radiator lower mounting pins to the rubber mounts.
    3. Fig 3: Removing & Installing Radiator Upper Mount Bracket & Rubber Mounts
    GM898634Courtesy of GENERAL MOTORS CORP.
  3. Position the upper radiator mounts over the upper pins.
    4. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Install the bolts which secure the radiator bracket to the rail.

    Tighten:  Tighten the bolts to 6 N.m (53 lb in).

  5. Raise the vehicle.
    6. Fig 4: Positioning Condenser Tabs Under Radiator Tabs
    GM894033Courtesy of GENERAL MOTORS CORP.
  6. Position the condenser tabs under the radiator tabs and install the bolts which secure the condenser to the radiator.

    Tighten:  Tighten the bolts to 4 N.m (35 lb in).

  7. Install the gasket between the lower radiator and the condenser.
  8. Install the bolt which secures the condenser hose clamp to the condenser.

    Tighten:  Tighten the bolt to 4 N.m (35 lb in).

    9. Fig 5: Removing & Installing Condenser Block Bolt From Radiator End Tank
    GM894382Courtesy of GENERAL MOTORS CORP.
  9. Install the bolt which secures the condenser block to the radiator end tank.

    Tighten:  Tighten the bolt to 4 N.m (35 lb in).

  10. Lower the vehicle.
  11. Remove the cap from the lower transmission cooler line.
    12. Fig 6: Removing & Installing Lower Transaxle Cooler Line From Radiator
    GM893763Courtesy of GENERAL MOTORS CORP.
  12. Install the lower transmission cooler line to the radiator end tank.

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

    13. Fig 7: Removing & Installing Lower Radiator Hose From Radiator
    GM894217Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The white line on the hose should be installed at the 12 o'clock position.
  13. Install the lower radiator hose to the radiator.

    Install the clamp to the 11 o'clock position.

  14. Remove the condenser support wire or plastic tie.
    15. Fig 8: Removing & Installing Fan Shroud-To-Radiator Bolts
    GM894533Courtesy of GENERAL MOTORS CORP.
  15. Install the fan and the shroud assembly onto the radiator lower tabs.
    16. IMPORTANT: Verify that the pusher fan electrical harness is not between the fan shroud and the radiator.
  16. Install the fan shroud bolts to the radiator.

    Tighten:  Tighten the bolts to 4 N.m (35 lb in).

    17. Fig 9: Removing & Installing Upper Transaxle Cooler Line From Radiator
    GM893761Courtesy of GENERAL MOTORS CORP.
  17. Remove the cap from the upper transmission oil cooler line.

    Install the line into the end tank retainer and snap into place.

  18. Install the upper transmission cooler line to radiator.

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

    19. Fig 10: Removing & Installing Forward Wiring Harness From Retaining Clips
    GM894726Courtesy of GENERAL MOTORS CORP.
  19. Install the forward wiring harness into the retaining clamps.
  20. Route the pusher fan electrical harness around the outside of the radiator end tank to the upper fan shroud.
    21. Fig 11: Connecting Cooling Fan Electrical Connectors & Connecting Connectors To Retainers
    GM894626Courtesy of GENERAL MOTORS CORP.
  21. Install the fan electrical connectors into the connector retainers as shown.
  22. Connect the fan electrical connectors.
  23. Install the wiring harness into the shroud retaining clamp.
  24. Install the pusher fan harness into the routing tabs on the fan shroud.
    25. Fig 12: Removing/Installing Upper Radiator Hose From Radiator
    GM894180Courtesy of GENERAL MOTORS CORP.
  25. Install the upper radiator hose to the radiator.
  26. Install the upper radiator hose clamp to 12 o'clock position.
  27. Install the battery. Refer to Battery Replacement in Battery.
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