GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL1/SC1 🢒 Engine 🢒 Engine Cooling 🢒 Radiator Replacement

Removal Procedure

    Object Number: 872300 Size: SH
  1. Remove the negative battery terminal.
  2. Drain the cooling system. Refer to Engine Coolant Check and Replacement .

    3. Object Number: 872946 Size: SH
  3. Remove the air intake duct, air filter box, and resonator.

    4. Object Number: 872917 Size: SH
  4. Remove the upper radiator clamp and hose from the radiator and fold the hose back.

    5. Object Number: 876756 Size: SH
  5. On models with an automatic transaxles, remove the upper transaxle oil cooler line.

    6. Object Number: 873173 Size: SH
  6. Remove the fan motor electrical connector.
  7. Remove the wiring harness from the fan shroud and radiator end tank.

    8. Object Number: 873175 Size: SH
  8. Lift the coolant fan off of the upper and lower mounting brackets.
  9. Remove the fan assembly from the vehicle.

    10. Object Number: 872919 Size: SH

    Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  10. Remove the lower radiator clamp and hose from the radiator.
  11. Raise the vehicle.

    12. Object Number: 860205 Size: SH
  12. Remove the lower splash shield.

    13. Object Number: 876763 Size: SH
  13. On models with an automatic transaxle, remove the lower transaxle oil cooler line.

    14. Object Number: 873172 Size: SH

    Important: Wire the condenser up to the vehicle to keep in place.

  14. Remove the two lower condenser bracket-to-radiator bolts.
  15. Lower the vehicle.

    16. Object Number: 872922 Size: SH
  16. Remove the upper radiator nuts and brackets.
  17. Remove the upper radiator seal.
  18. Remove the radiator from the vehicle.

Installation Procedure

    Object Number: 872245 Size: SH
  1. Install the radiator in the vehicle.
  2. Install the upper radiator seal.

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

    Important: The L-shaped brackets must not pinch the radiator locating pins. The radiator must be able to move freely in the grommets after installation.

  3. Install the upper radiator brackets and nuts.

    4. Tighten
    Tighten the radiator support brackets to 10 N·m (89 lb in).


    Object Number: 873172 Size: SH

    Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  4. Raise the vehicle.
  5. Install the two lower condenser bracket-to-radiator bolts and remove support wire.

    6. Tighten
    Tighten the lower condenser bracket-to-radiator bolts to 6 N·m (53 lb in).


    Object Number: 876763 Size: SH
  6. On models with an automatic transaxle, install the lower transaxle oil cooler line.

    7. Tighten
    Tighten the lower transaxle oil cooler line 14 N·m (10 lb ft).


    Object Number: 860205 Size: SH
  7. Install the lower splash shield.
  8. Lower the vehicle.

    9. Object Number: 872927 Size: SH
  9. Install the lower radiator hose and clamp. Position the clamp at 11 o'clock.

    10. Object Number: 876926 Size: SH
  10. Install the fan assembly.

    11. Object Number: 873173 Size: SH
  11. Install the upper hold down bolt.

    12. Tighten
    Tighten the upper hold down bolt to 6 N·m (53 lb in).

  12. Install the fan motor electrical connector.
  13. Install the wiring harness to the fan shroud and radiator end tank.

    14. Object Number: 873128 Size: SH
  14. On vehicles with an automatic transaxle, install and tighten the upper transaxle oil cooler line.
  15. Install the upper transaxle oil cooler line at a 35 degree angle to the vertical center line of the radiator end tank and hold while tightening.

    16. Tighten
    Tighten the upper transaxle oil cooler line to 14 N·m (10 lb ft).


    Object Number: 872917 Size: SH
  16. Install the upper radiator hose and clamp. Position the clamp at 1 o'clock.

    17. Tighten
    Tighten the upper radiator hose and clamp to 3.5 N·m (31 lb in).


    Object Number: 872946 Size: SH
  17. Install the air filter box, intake air duct, and resonator.
  18. Connect the negative battery terminal.

    19. Tighten
    Tighten the battery terminal bolts to 17 N·m (13 lb ft).

  19. Fill with coolant and leak test. Refer to Engine Coolant Check and Replacement .