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Removal Procedure

WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disable the SIR system. Refer to DISABLING & ACTIVATING AIR BAG SYSTEM .
  2. Drain the cooling system. Refer to Draining and Filling Cooling System (L61) .
  3. Remove the hood latch. Refer to HOOD LATCH REPLACEMENT .
  4. Remove the right and left headlamp assemblies. Refer to HEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT (PONTIAC) in Lighting Systems.
  5. Remove the radiator upper mounting bolts (1) and the upper radiator mounts (2).
    Fig 1: Removing Radiator Upper Mounting Bolts & Upper Radiator Mounts
    G01580927Courtesy of GENERAL MOTORS CORP.
  6. Raise the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  7. Disconnect the forward discriminating sensor harness. Refer to ZONE 1 .
  8. Remove the cooling fan assembly. Refer to Cooling Fan Replacement - Electric .
  9. Use the J 38185  in order to reposition the radiator outlet hose clamp from the radiator.
    Fig 2: Disconnecting Hoses At Radiator
    G01580928Courtesy of GENERAL MOTORS CORP.
  10. Remove the radiator outlet hose from the radiator.
  11. Remove the lower transmission oil cooler line from the radiator.
    Fig 3: Disconnecting Transmission Oil Cooler Lines At Radiator
    G01580929Courtesy of GENERAL MOTORS CORP.
  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 .
  14. Remove the upper transmission oil cooler line from the radiator.
  15. Use the J 38185  in order to reposition the radiator inlet hose from the radiator.
  16. Remove the surge tank inlet hose and the clamp (1) from the radiator.
    Fig 4: Disconnecting Surge Tank Hose At Radiator
    G01580930Courtesy of GENERAL MOTORS CORP.
  17. Remove condenser to radiator mounting bolts (2).
  18. Remove the condenser from the radiator, if equipped. The radiator can be removed without discharging the A/C System.
  19. Remove the radiator assembly from the vehicle.
    Fig 5: Removing/Installing Radiator
    G01580931Courtesy of GENERAL MOTORS CORP.
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