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Home >> Saturn >> 2003 >> L200 Standard >> Repair and Diagnosis >> Engine Mechanical >> Cooling System (Mechanical) >> Engine Cooling >> Repair Instructions >> Radiator Replacement (L81) >> Installation Procedure

Installation Procedure

    Fig 1: Removing & Installing Gaskets Separating Upper & Lower Radiator From Condenser
    GM894311Courtesy of GENERAL MOTORS CORP.
  1. Install the gaskets between the upper and lower 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 into the rubber mounts.
    3. Fig 3: Removing & Installing Radiator Coolant Air Bleed Hose From Radiator
    GM894532Courtesy of GENERAL MOTORS CORP.
  3. Install the radiator coolant air bleed hose to the radiator.
  4. Install the radiator coolant air bleed hose clamp at the 1 o'clock position.
  5. Install the wiring clips to the upper radiator mounting bracket.
    6. Fig 4: Removing & Installing Radiator Upper Mount Bracket & Rubber Mounts
    GM898634Courtesy of GENERAL MOTORS CORP.
  6. Position the upper radiator mounts over the upper pins.
    7. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  7. Install the radiator bracket bolts

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

  8. Install the wiring clips to the upper radiator mount bracket.
    9. Fig 5: Positioning Condenser Tabs Under Radiator Tabs
    GM894033Courtesy of GENERAL MOTORS CORP.
  9. Position the condenser tabs under the radiator tabs.
  10. Install the condenser to radiator bolts.

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

    11. Fig 6: Removing & Installing Gaskets Separating Upper & Lower Radiator From Condenser
    GM894311Courtesy of GENERAL MOTORS CORP.
  11. Install the lower radiator to the condenser gasket.
    12. Fig 7: Removing & Installing Condenser Block Bolt From Radiator End Tank
    GM894382Courtesy of GENERAL MOTORS CORP.
  12. Install the bolt which secures the condenser block to the radiator end tank.

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

  13. Remove the condenser support wire or the plastic tie.
    14. Fig 8: Removing & Installing Lower Transaxle Cooler Line From Radiator
    GM893763Courtesy of GENERAL MOTORS CORP.
  14. Remove the cap and install the lower transaxle cooler line to radiator.

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

    15. Fig 9: Removing & Installing Lower Radiator Hose From Radiator
    GM893929Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The white line on the hose should be installed at the 12 o'clock position.
  15. Install the lower radiator hose to the radiator.

    Install the clamp at the 11 o'clock position.

    16. Fig 10: Removing & Installing Forward Wiring Harness From Retaining Clips
    GM894726Courtesy of GENERAL MOTORS CORP.
  16. Install the forward wiring harness into the forward rail clips.
    17. Fig 11: Installing Fan & Shroud Assembly Onto Radiator Lower Tabs
    GM894552Courtesy of GENERAL MOTORS CORP.
  17. Install the fan and shroud assembly onto the radiator lower tabs.
    18. Fig 12: Removing & Installing Engine Cooling Fan
    GM894328Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Verify that the pusher fan electrical harness is not between the fan shroud and the radiator.
  18. Install the bolts that secure the fan shroud to the radiator.

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

    19. Fig 13: Removing & Installing Upper Transaxle Cooler Line From Radiator
    GM893761Courtesy of GENERAL MOTORS CORP.
  19. Install the upper transaxle oil cooler line into the radiator end tank retainer.
  20. Remove the cap from the oil cooler line.
  21. Install the oil cooler line to the radiator.

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

    22. Fig 14: Connecting Cooling Fan Electrical Connectors & Connecting Connectors To Retainers
    GM894626Courtesy of GENERAL MOTORS CORP.
  22. Route the pusher fan electrical harness around the outside of the radiator end tank to the upper fan shroud.
  23. Install the fan electrical connectors to the connector retainers as shown.
  24. Connect the fan electrical connectors.
  25. Install the pusher fan harness under the routing tabs on the fan shroud.
    26. Fig 15: Removing/Installing Upper Radiator Hose From Radiator
    GM894180Courtesy of GENERAL MOTORS CORP.
  26. Install the upper radiator hose to the radiator.

    Install the clamp to the 12 o'clock position.

    27. Fig 16: Removing & Installing Power Steering Fluid Reservoir
    GM894561Courtesy of GENERAL MOTORS CORP.
  27. Install the bolts which secure the power steering fluid reservoir to the fan shroud.

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

    28. Fig 17: View Of Battery, Fan Control Module & Battery Hold-Down Bracket
    GM886658Courtesy of GENERAL MOTORS CORP.
  28. Install the battery. Refer to Battery Replacement in Battery.
  29. Install the fan control module by sliding down onto the bracket.
  30. Fill the cooling system. Refer to Draining and Filling Cooling System .
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