GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Malibu 🢒 Engine 🢒 Engine Cooling 🢒 Cooling Fan and Shroud Replacement

Removal Procedure
  1. Drain the cooling system. Refer to Cooling System Draining and Filling.
  2. Remove the air cleaner air duct. Refer to the following:
    3. •  Air Cleaner Outlet Duct Replacement for the 2.4L engine
    •  Air Cleaner Inlet Duct Replacement for the 3.5L engine
    •  Air Cleaner Inlet Duct Replacement for the 3.6L engine
  3. Remove the upper radiator air deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
  4. Remove the transmission oil cooler pipes from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4T45-E transaxle.

    5. Object Number: 1202407 Size: SH
  5. Loop a rope around each of the upper 2 tabs of the condenser and tie a rope around the upper tie bar.

    6. Object Number: 1672182 Size: SH
  6. Remove the upper radiator support bracket bolts.

    7. Object Number: 1672180 Size: SH
  7. Remove the upper radiator support brackets.

    8. Object Number: 1202424 Size: SH
  8. Pry upward on the fan shroud tabs at the radiator clips to release the fan shroud from the radiator.
  9. Remove the lower radiator air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement.
  10. Lower the vehicle.
  11. Remove the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement.
  12. Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement.
  13. Disconnect the cooling fan wire harness connectors.
  14. Remove the A/C compressor and condenser hose assembly. Refer to Air Conditioning Compressor and Condenser Hose Replacement.
  15. Raise the vehicle.

    16. Object Number: 1203468 Size: SH
  16. Remove the lower radiator support bracket bolts.
  17. Remove the lower radiator support brackets.

    18. Object Number: 1203515 Size: SH
  18. Remove the transmission oil cooler pipe clip from the fan shroud.

    19. Object Number: 1202428 Size: SH
  19. Remove the fan shroud assembly.

Installation Procedure

    Object Number: 1202428 Size: SH
  1. Install the fan shroud assembly.
  2. Install the transmission oil cooler pipes to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4T45-E transaxle.

    3. Object Number: 1203515 Size: SH
  3. Install the transmission oil cooler pipe clip to the fan shroud.

    4. Object Number: 1203468 Size: SH
  4. Install the lower radiator support brackets.

    5. Caution: Refer to Fastener Caution in the Preface section.

  5. Install the lower radiator support bracket bolts and tighten to 60 N·m (44 lb ft).
  6. Install the cooling fan wire harness connectors.
  7. Install the radiator outlet hose to the radiator. Refer to Radiator Outlet Hose Replacement.
  8. Install the lower radiator air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement.
  9. Lower the vehicle.

    10. Object Number: 1212433 Size: SH
  10. Snap fan shroud tabs into the radiator clips.
  11. Remove the rope attached to the condenser and upper tie bar.

    12. Object Number: 1672180 Size: SH
  12. Install the upper radiator support brackets.

    13. Object Number: 1672182 Size: SH
  13. Install the upper radiator support bracket bolts and tighten to 10 N·m (89 lb in).
  14. Install the radiator inlet hose to the radiator. Refer to Radiator Inlet Hose Replacement.
  15. Install the A/C compressor and condenser hose assembly. Refer to Air Conditioning Compressor and Condenser Hose Replacement.
  16. Install the upper radiator air deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
  17. Install the air cleaner air duct. Refer to the following:
    18. •  Air Cleaner Outlet Duct Replacement for the 2.4L engine
    •  Air Cleaner Inlet Duct Replacement for the 3.5L engine
    •  Air Cleaner Inlet Duct Replacement for the 3.6L engine
  18. Fill the cooling system. Refer to Cooling System Draining and Filling.
  19. Inspect the transmission fluid level. Refer to Transmission Fluid Check for the 4T45-E transaxle or Transmission Fluid Check for the 6T70/6T75 transaxle.