GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Engine 🢒 Engine Cooling 🢒 Radiator Replacement

Removal Procedure

    Warning: Refer to Battery Disconnect Warning in the Preface section.

  1. Open the hood.
  2. Disconnect the battery.
    3. • Disconnect the negative connection.
    • Loosen the nut.

    Object Number: 1943992 Size: SH
  3. Remove the upper grille.
    4. • Remove the 4 body-bound rivets (1).
    • Remove from the front fascia from above.
    • Remove the 6 clips.

    Object Number: 1943996 Size: SH
  4. Remove the front fascia at the top.
    5. • Remove the 2 bolts (1).
    • Remove the 2 body-bound rivets (2).
    • Disconnect the wiring harness connector.
  5. Raise the vehicle by half its height.

    6. Object Number: 1943998 Size: LH
  6. Remove the front fascia.
    7. • Remove the 6 body-bound rivets (2).
    • Remove the 4 bolts (1).
  7. Raise the vehicle by half its height.

    8. Object Number: 1936581 Size: SH
  8. Drain the coolant.
    9. • Place a drain pan underneath.
    • Install the suitable hose to the drain connection (2).
    • Open the coolant drain screw (1).
    • Drain the coolant.
    • Close the coolant drain screw.

    Object Number: 1936587 Size: SH
  9. Disconnect the cooling module wiring harness plug (1).
  10. Place a drain pan underneath.
  11. Remove the 2 radiator hoses from the radiator.

    12. Remove 2 clamps.

  12. Lower the vehicle by its full height.
  13. Remove the coolant hose from the radiator.
    14. • Release the clamp.
    • Remove the coolant hose.
  14. Remove the 2 coolant hoses.
    15. • Remove the radiator hose (top) from the bracket.
    • Remove the coolant hose from the fan housing.

    Object Number: 1939096 Size: SH
  15. For vehicles equipped with an automatic transmission:
    16. • Remove the lower oil cooling line (2) with the connecting hose from the oil cooler.
    • Remove the banjo bolt.
    • Remove the upper oil cooling line (1) with the connecting hose from the oil cooler.
    • Remove the banjo bolt.

    Object Number: 1936659 Size: SH
  16. Remove the fan housing from the radiator.
    17. • Remove the 2 bolts (1).
    • Pull the 2 brackets (2) upward out of the radiator.

    Object Number: 1944311 Size: LH
  17. Secure the radiator to the upper brackets (1).

    18. Insert 2 suitable tools.


    Object Number: 1944371 Size: LH
  18. Remove the condenser from the radiator.
    19. • Secure the condenser to the upper front with the retaining straps (1).
    • Remove the 4 bolts (2, 3).
  19. Raise the vehicle by its full height.

    20. Object Number: 1940560 Size: SH

    Note: Inspect the installation position.

  20. Remove the lower radiator bracket (1) from the front axle body.

    21. Remove the 4 bolts.

  21. Lower the radiator down and out.
    22. • Remove the fuses from the upper holders.
    • Push the condenser forward.

       Note: These operations must only be performed if the component is being replaced.

    • Remove the attached parts from the radiator.
    • Remove the 2 rubber bearings.
    • Pull away the 6 sheet metal nuts.
    • Remove the coolant temperature sensor.

Installation Procedure
  1. Install the attaching parts to the radiator.
    2. • Install the 2 rubber bushes.
    • Push on the 6 sheet metal nuts.
    • Install the coolant temperature sensor.
  2. Insert the radiator from below.

    3. Secure to the upper radiator with a suitable tool.

    Caution: Refer to Fastener Caution in the Preface section.

    Note: Arrow on bracket points to the front of the vehicle.

  3. Install the lower radiator bracket.

    4. Tighten
    Tighten the 4 bolts to 15 N·m (11 lb ft).

  4. Remove the fuses.
  5. Lower the vehicle by half its height.
  6. Install the condenser to the radiator.

    7. Tighten
    Tighten the 4 bolts to 5 N·m (44 lb in).

  7. Remove the retaining straps.
  8. Lower the vehicle by half its height.
  9. Install the fan housing.
    10. • Insert in bracket at the bottom of the radiator.

    Tighten
    Tighten the 2 bolts to 5 N·m (44 lb in).

    • Install the 2 radiator hoses into the bracket.
    • Install the NEW cable tie.
  10. Install the expansion tank coolant hose to the radiator.
    11. • Fasten the clamp.
    • Install the coolant hose.
  11. Raise the vehicle by its full height.
  12. Install the lower oil cooling line with the connecting hose on the oil cooler.

    13. Use NEW seal rings.

    Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  13. Install the upper oil cooling line with the connecting hose on the oil cooler.

    14. Use NEW seal rings.

    Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  14. Install the 2 coolant hoses to the radiator.

    15. Install the 2 clamps.

  15. Connect the fan wiring harness plug.
  16. Lower the vehicle by half its height.
  17. Install the front fascia.
    18. • Connect the 2 wiring harness plugs.
    • Install the front fascia on the side.
  18. Install the front paneling at bottom.

    19. Install the 6 body-bound rivets.

    Tighten
    Tighten the 4 bolts to 2.5 N·m (22 lb in).

  19. Lower the vehicle by half its height.
  20. Install the fascia at top.

    21. Fasten the 2 body-bound rivets.

    Tighten
    Tighten the 2 bolts to 2.5 N·m (22 lb in).

  21. Install the radiator grille.
    22. • Install the 6x.
    • Install the 4 body-bound rivets.
  22. Fill and bleed the cooling system. Refer to Cooling System Draining and Filling.
  23. Connect the battery.

    24. Connect the negative connection.

    Tighten
    Tighten the nut to 5 N·m (44 lb in).

  24. For reprogramming procedures, refer to Control Module References.
  25. Close the hood.