GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2000 🢒 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.

    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.

  1. Disconnect the negative battery cable.
  2. Disable the SIR system. Refer to Disabling the SIR System in Supplemental Inflatable Restraint (SIR) System.
  3. Drain the engine coolant. Recover the coolant. Refer to Cooling System Draining and Filling .
  4. Remove the hood latch support from the radiator upper tie bar. Refer to Hood Latch Support Replacement in Body Front End.
  5. Remove the right and left headlamp assemblies. Refer to Headlamp Replacement in Lighting Systems.

    6. Object Number: 25877 Size: SH
  6. Remove the radiator upper mounting bolts (1) and the upper radiator mounts (2).
  7. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  8. Disconnect the forward discriminating sensor harness. Refer to Enabling the SIR System in Supplemental Inflatable Restraint (SIR) System.
  9. Remove the cooling fan assembly. Refer to Engine Cooling Fan Replacement .

    10. Object Number: 12064 Size: SH

  10. Disconnect the radiator outlet hose from the radiator.


    Object Number: 12063 Size: SH
  11. Disconnect the lower transmission oil cooler line from the radiator.
  12. Lower the vehicle.
  13. Remove the hood latch support bracket and the forward discriminating sensor with the harness. Refer to Hood Latch Support Replacement in Body Front End.
  14. Disconnect the upper transmission oil cooler line from the radiator.
  15. Disconnect the radiator inlet hose from the radiator.

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

    17. Object Number: 25811 Size: SH
  17. Remove the condenser from the radiator, if equipped. It is not necessary to discharge the A/C System.
  18. Remove the radiator assembly from the vehicle.

Installation Procedure

    Object Number: 25811 Size: SH
  1. Install the radiator assembly to the vehicle.
  2. Install the condenser to the radiator.

    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 Support Replacement in Body Front End.
  5. Route the forward discriminating sensor harness. Refer to Inflatable Restraint Front End Discriminating Sensor Replacement Supplemental Inflatable Restraint (SIR) System.
  6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  7. Install the cooling fan assembly. Refer to Engine Cooling Fan Replacement .

    8. Object Number: 12063 Size: SH

    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.

  8. Connect the lower transmission oil cooler line to the radiator.

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


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

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

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


    Object Number: 25877 Size: SH
  14. Install the upper radiator mount bolts (1) to the upper tie bar.

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

  15. Install the hood latch support. Refer to Hood Latch Support Replacement in Body Front End.
  16. Install the right and the left headlamp assemblies. Refer to Headlamp Replacement in Lighting Systems.
  17. Install and adjust the hood latch assembly. Refer to Hood Latch Support Replacement in Body Front End.
  18. Refill the cooling system. Refer to Cooling System Draining and Filling .
  19. Enable the SIR system. Refer to Enabling the SIR System in Supplemental Inflatable Restraint (SIR) System.
  20. Connect the negative battery cable.

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

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