GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Tracker - 4WD 🢒 Engine 🢒 Engine Controls - 2.5L (LE8) 🢒 Radiator Replacement

Removal Procedure

    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.

    Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

  1. Disconnect the negative battery cable.
  2. Remove the radiator cap.
  3. Raise and properly support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Remove the lower radiator shroud clips.

    5. Object Number: 466476 Size: SH
  5. Open the drain plug (1).
  6. Drain the cooling system.
  7. Close the drain plug (1).

    8. Object Number: 465595 Size: SH
  8. Remove the transmission oil cooler lines (1) from the bottom of the radiator (automatic transmission only). Cap the open lines to prevent leakage.

    9. Object Number: 465596 Size: SH
  9. Remove the lower radiator hose.
  10. Lower the vehicle then remove the radiator overflow hose.
  11. Remove the upper radiator hose.
  12. Remove the 2 upper radiator shroud clips.

    13. Object Number: 465590 Size: SH
  13. Remove 1 bolt from each side of the radiator.

    14. Important: Do not damage the radiator on the fan during removal.

  14. Lean the fan shroud toward the engine and lift the radiator up and out of the vehicle.

Installation Procedure

    Object Number: 465590 Size: SH

    Important: Do not damage the radiator on the fan during installation.

  1. Install the radiator and secure with 1 bolt on each side of the radiator.
  2. Install the 2 upper radiator shroud clips.
  3. Install the upper radiator hose.
  4. Install the radiator overflow hose.
  5. Raise and properly support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    6. Object Number: 465596 Size: SH
  6. Install the lower radiator hose.

    7. Object Number: 465595 Size: SH
  7. Install the transmission oil cooler lines (1) to the bottom of the radiator (automatic transmission only).

    8. Install the 2 lower radiator shroud clips.

  8. Lower the vehicle.
  9. Fill the cooling system. Refer to Cooling System Draining and Filling
  10. Connect the negative battery cable.
  11. Run the engine and inspect for the following:
    12. • Coolant leaks
    • Correct cooling level
    • Automatic transmission fluid leaks
    • Correct automatic transmission fluid level