GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1996 🢒 Sunfire 🢒 Engine 🢒 Engine Cooling 🢒 Radiator Replacement

Removal Procedure

    Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.

  1. Disconnect the negative battery cable. Refer to

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

    in General Information.
  2. If the vehicle is equipped with air conditioning, recover the refrigerant. Refer to Heating and Air Conditioning.
  3. Disable the SIR system. Refer to Disabling the SIR System in Steering Wheel and Column.
  4. Drain the engine coolant. Recover the coolant. Refer to Cooling System Draining and Filling .
  5. Remove the hood latch support from the radiator upper tie bar. Refer to Hood Latch and Cover in Body Front End.
  6. Remove the right and left headlamp assemblies. Refer to Lighting Systems and Horns in Electrical.

    7. Object Number: 25877 Size: SH
  7. Remove the radiator upper mounting bolts (1) and the upper radiator mounts (2).
  8. Raise the vehicle. Refer to General Information.
  9. Disconnect the forward discriminating sensor harness. Refer to Forward Discriminating Sensor in Supplemental Inflatable Restraint (SIR) System.
  10. Remove the cooling fan assembly. Refer to Electric Cooling Fan .

    11. Object Number: 12064 Size: SH
  11. Disconnect the radiator outlet hose from the radiator.
  12. Disconnect the lower transmission oil cooler line from the radiator.
  13. Lower the vehicle.
  14. Remove the hood latch support bracket and the forward discriminating sensor with the harness. Refer to Hood Latch and Cover in Body Front End.
  15. Disconnect the upper transmission oil cooler line from the radiator.
  16. Disconnect the radiator inlet hose from the radiator.
  17. Disconnect the compressor and the accumulator hoses from the condenser, if equipped. Discard the o-rings. Refer to O-Rings in Air Conditioning.

    18. Object Number: 25819 Size: SH
  18. Disconnect the surge tank inlet hose and the clamp (1) from the radiator.

    19. Object Number: 25811 Size: SH
  19. Remove the radiator/condenser assembly from the vehicle.
  20. Remove the condenser from the radiator, if equipped. Refer to Condenser in Air Conditioning.

Installation Procedure

    Object Number: 25811 Size: SH
  1. Install the condenser to the radiator, if equipped. Refer to Condenser in Air Conditioning.
  2. Install the radiator/condenser assembly to the vehicle.

    3. Object Number: 25819 Size: SH
  3. Connect the surge tank overflow hose to the radiator.
  4. Install the hood latch bracket. Refer to Hood Latch and Cover in Body Front End. Route the forward discriminating sensor harness. Refer to Supplemental Inflatable Restraint (SIR) System.
  5. Raise the vehicle. Refer to General Information.
  6. Install the cooling fan assembly. Refer to Electric Cooling Fan .

    7. Object Number: 12063 Size: SH
  7. Connect the lower transmission oil cooler line to the radiator.

    8. Tighten
    Tighten the lower transmission oil cooler line to 36 N·m (27 lb ft).

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.


    Object Number: 12064 Size: SH
  8. Connect the radiator outlet hose to the radiator.
  9. Connect the forward discriminating sensor harness connector. Refer to Supplemental Inflatable Restraint (SIR) System.
  10. Lower the vehicle.
  11. Connect the radiator inlet hose to the radiator.

    12. Object Number: 12063 Size: SH
  12. Connect the upper transmission oil cooler line to the radiator.

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


    Object Number: 25877 Size: SH
  13. Install the upper radiator mount bolts to the upper tie bar.

    14. Tighten
    Tighten the radiator upper mount bolts to 10 N·m (89 lb in).

  14. Install the hood latch support. Refer to Hood Latch and Cover in Body Front End.
  15. Connect the compressor and accumulator hoses to the condenser, if equipped. Use new o-rings.
  16. Install the right and the left headlamp assemblies. Refer to Hood Latch and Cover in Body Front End.
  17. Install and adjust the hood latch assembly. Refer to Hood Latch and Cover in Body Front End.
  18. Refill the cooling system. Refer to Cooling System Draining and Filling .
  19. Recharge the A/C system, if equipped. Refer to Charging in Air Conditioning.
  20. Enable the SIR system. Refer to Enabling the SIR System in Steering Wheel and Column.
  21. Connect the negative battery cable.

    22. Tighten
    Tighten the negative battery cable bolt to 15 N·m (11 lb ft).

  22. Start the engine. After the engine reaches normal operating temperature, check for coolant leaks.