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For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu Classic 🢒 Engine 🢒 Engine Cooling 🢒 Radiator Replacement

Radiator Replacement L61

Special Tools

J 38185 Hose Clamp Pliers

Removal Procedure
  1. Drain the coolant. Refer to Cooling System Draining and Filling .
  2. Remove the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
  3. Remove the right headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .

    4. Object Number: 1202407 Size: SH
  4. Loop a rope around each of the 2 tabs of the condenser and tie the rope around the upper tie bar.
  5. Remove the upper radiator support bracket bolts.

    6. Object Number: 1202411 Size: SH
  6. Remove the upper radiator support brackets.
  7. Reposition the radiator outlet hose clamp at the radiator using the J 38185 .
  8. Remove the radiator outlet hose from the radiator.

    9. Object Number: 1203448 Size: SH
  9. Reposition the radiator inlet hose clamp at the radiator using the J 38185 .
  10. Remove the radiator inlet hose from the radiator.

    11. Object Number: 1203453 Size: SH

    Object Number: 1203537 Size: SH
  11. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  12. Remove the lower radiator air deflector retainers.
  13. Remove the lower radiator air deflector.

    14. Object Number: 1203534 Size: SH
  14. Remove the right front fender liner. Refer to Front Fender Liner Replacement .
  15. Remove the right radiator air deflector retainers.
  16. Remove the right radiator air deflector.

    17. Object Number: 1203536 Size: SH
  17. Remove the left radiator air deflector retainers.
  18. Remove the left radiator air deflector.
  19. Place a drain pan under the transmission oil cooler pipes.
  20. Remove the transmission oil cooler pipes attachment nut from the transmission.
  21. Remove the transmission oil cooler pipes from the transmission.

    22. Object Number: 1203519 Size: SH

    Object Number: 1203468 Size: SH
  22. Remove the lower radiator support bracket bolts.
  23. Remove the lower radiator support brackets.
  24. Remove the radiator lower mounts.
  25. Remove and discard the condenser mounting bolts.

    26. Object Number: 1203511 Size: SH
  26. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.

    27. Object Number: 1201922 Size: SH
  27. Remove and discard the condenser mounting nuts from the radiator.

    28. Object Number: 1336545 Size: SH
  28. Remove the radiator air side seals.

    29. Object Number: 1202420 Size: SH
  29. Remove the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
  30. Remove the transmission oil cooler pipes from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .
  31. Pry upward on the fan shroud tabs at the radiator clips.

    32. Object Number: 1202424 Size: SH
  32. Remove the cooling fan and shroud assembly from the radiator.

Installation Procedure
  1. Install the cooling fan and shroud assembly to the radiator.

    2. Object Number: 1212433 Size: SH
  2. Snap the fan shroud tabs into the radiator clips.
  3. Install the transmission oil cooler pipes to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .

    4. Object Number: 1202420 Size: SH
  4. Install the radiator, cooling fan shroud and transmission oil cooler pipe assembly.

    5. Object Number: 1336545 Size: SH
  5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.

    6. Notice: The bolt retaining the condenser to the radiator end tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.

    Important: Replace the condenser mounting bolts and nuts.


    Object Number: 1201922 Size: SH
  6. Install the condenser mounting nuts to the radiator.
  7. Insert the condenser mounting tabs into the radiator clips.

    8. Notice: Refer to Fastener Notice in the Preface section.

  8. Install the condenser mounting bolts.

    9. Object Number: 1203511 Size: SH

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


    Object Number: 1336474 Size: SH
  9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.

    10. Object Number: 1337348 Size: SH
  10. The radiator air side seals must be in the proper position for proper air flow.

    11. Important: Replace the radiator lower mounts as a pair or vibration may result.

  11. Install the radiator lower mounts.

    12. Object Number: 1203468 Size: SH
  12. Install the lower radiator support brackets.
  13. Install the lower radiator support bracket bolts.

    14. Tighten
    Tighten the bolts to 60 N·m (44 lb ft).

  14. Install the transmission oil cooler pipes to the transmission.

    15. Object Number: 1203519 Size: SH
  15. Install the transmission oil cooler pipes attachment nut to the transmission.

    16. Tighten
    Tighten the nut to 7 N·m (62 lb in).


    Object Number: 1203536 Size: SH

    Important: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.

  16. Install the left radiator air deflector.
  17. Install the left radiator air deflector retainers.

    18. Object Number: 1203534 Size: SH
  18. Install the right radiator air deflector.
  19. Install the right radiator air deflector retainers.
  20. Install the right front fender liner. Refer to Front Fender Liner Replacement .

    21. Object Number: 1203537 Size: SH
  21. Install the lower radiator air deflector.
  22. Install the lower radiator air deflector retainers.
  23. Lower the vehicle.
  24. Install the radiator inlet hose to the radiator.

    25. Object Number: 1203453 Size: SH
  25. Reposition the radiator inlet hose clamp at the radiator using the J 38185 .
  26. Install the radiator outlet hose to the radiator.

    27. Object Number: 1203448 Size: SH
  27. Reposition the radiator outlet hose clamp at the radiator using the J 38185 .
  28. Remove the rope attached to the condenser and upper tie bar.

    29. Object Number: 1202411 Size: SH
  29. Install the upper radiator support brackets.

    30. Important: Do not allow the upper bracket to twist when tightening the screw or vibration may result.


    Object Number: 1212430 Size: SH
  30. Install the upper radiator support bracket bolts.

    31. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  31. Install the right headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
  32. Install the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
  33. Fill the coolant. Refer to Cooling System Draining and Filling .
  34. Inspect the transmission fluid level. Refer to Transmission Fluid Check .

Radiator Replacement LZ4

Special Tools

J 38185 Hose Clamp Pliers

Removal Procedure
  1. Drain the coolant. Refer to Cooling System Draining and Filling .
  2. Remove the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
  3. Remove the right headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .

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

    5. Object Number: 1202411 Size: SH
  5. Remove the upper radiator support bracket bolts.
  6. Remove the upper radiator support brackets.

    7. Object Number: 1215548 Size: SH
  7. Reposition the surge tank outlet hose clamp at the radiator using the J 38185 .
  8. Remove the surge tank outlet hose from the radiator.

    9. Object Number: 1203452 Size: SH
  9. Reposition the radiator inlet hose clamp at the radiator using the J 38185 .
  10. Remove the radiator inlet hose from the radiator.
  11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

    12. Object Number: 1203537 Size: SH
  12. Remove the lower radiator air deflector retainers.
  13. Remove the lower radiator air deflector.

    14. Object Number: 1203530 Size: SH
  14. Remove the right front fender liner. Refer to Front Fender Liner Replacement .
  15. Remove the right radiator air deflector retainers.
  16. Remove the right radiator air deflector.

    17. Object Number: 1203535 Size: SH
  17. Remove the left radiator air deflector retainers.
  18. Remove the left radiator air deflector.

    19. Object Number: 1203449 Size: SH
  19. Reposition the radiator outlet hose clamp at the radiator using the J 38185 .
  20. Remove the radiator outlet hose from the radiator.

    21. Object Number: 1203519 Size: SH
  21. Place a drain pan under the transmission oil cooler pipes.
  22. Remove the transmission oil cooler pipe attachment nut from the transmission.
  23. Remove the transmission oil cooler pipes from the transmission.

    24. Object Number: 1203468 Size: SH
  24. Remove the lower radiator support bracket bolts.
  25. Remove the lower radiator support brackets.
  26. Remove the radiator lower mounts.

    27. Object Number: 1203511 Size: SH
  27. Remove and discard the condenser mounting bolts from the radiator.

    28. Object Number: 1201922 Size: SH
  28. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
  29. Remove and discard the condenser mounting nuts from the radiator.

    30. Object Number: 1336545 Size: SH
  30. Remove the radiator air side seals.

    31. Object Number: 1202423 Size: SH
  31. Remove the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
  32. Remove the transmission oil cooler pipes from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .

    33. Object Number: 1202424 Size: SH
  33. Pry upward on the fan shroud tabs at the radiator clips.
  34. Remove the cooling fan and shroud assembly.

Installation Procedure

    Object Number: 1212433 Size: SH
  1. Install the cooling fan and shroud assembly to the radiator.
  2. Snap the fan shroud tabs into the radiator clips.
  3. Install the transmission oil cooler pipes to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .

    4. Object Number: 1202423 Size: SH
  4. Install the radiator, cooling fan shroud and transmission oil cooler pipe assembly.

    5. Object Number: 1336545 Size: SH
  5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.

    6. Object Number: 1201922 Size: SH

    Notice: The bolt retaining the condenser to the radiator end tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.

    Important: Replace the condenser mounting bolts and nuts.

  6. Install the condenser mounting nuts to the radiator.
  7. Insert the condenser mounting tabs into the radiator clips.

    8. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1203511 Size: SH
  8. Install the condenser to the radiator bolts.

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


    Object Number: 1336474 Size: SH
  9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.

    10. Object Number: 1337348 Size: SH
  10. The radiator air side seals must be in the proper position for proper air flow.

    11. Important: Replace the radiator lower mounts as a pair or vibration may result.

  11. Install the radiator lower mounts.

    12. Object Number: 1203468 Size: SH
  12. Install the lower radiator support brackets.
  13. Install the lower radiator support bracket bolts.

    14. Tighten
    Tighten the bolts to 60 N·m (44 lb ft).


    Object Number: 1203519 Size: SH
  14. Install the transmission oil cooler pipes to the transmission.
  15. Install the transmission oil cooler pipes attachment nut to the transmission.

    16. Tighten
    Tighten the nut to 7 N·m (62 lb in).


    Object Number: 1203449 Size: SH
  16. Install the radiator outlet hose to the radiator.
  17. Reposition the radiator outlet hose clamp at the radiator using the J 38185 .

    18. Object Number: 1203535 Size: SH

    Important: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.

  18. Install the left radiator air deflector.
  19. Install the left radiator air deflector retainers.

    20. Object Number: 1203530 Size: SH
  20. Install the right radiator air deflector.
  21. Install the right radiator air deflector retainers.
  22. Install the right front fender liner. Refer to Front Fender Liner Replacement .

    23. Object Number: 1203537 Size: SH
  23. Install the lower radiator air deflector.
  24. Install the lower radiator air deflector retainers.
  25. Lower the vehicle.

    26. Object Number: 1203452 Size: SH
  26. Install the radiator inlet hose to the radiator.
  27. Reposition the radiator inlet hose clamp at the radiator using the J 38185 .

    28. Object Number: 1215548 Size: SH
  28. Install the surge tank outlet hose to the radiator.
  29. Reposition the surge tank outlet hose clamp at the radiator using the J 38185 .
  30. Remove the rope attached to the condenser and upper tie bar.

    31. Object Number: 1212430 Size: SH
  31. Install the upper radiator support brackets.

    32. Object Number: 1202411 Size: SH

    Important: Do not allow the upper bracket to twist when tightening the screw or vibration may result.

  32. Install the upper radiator support bracket bolts.

    33. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  33. Install the right headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
  34. Install the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
  35. Fill the coolant. Refer to Cooling System Draining and Filling .
  36. Inspect the transmission fluid level. Refer to Transmission Fluid Check .