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Removal Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1 in SIR.
  2. Drain the cooling system. Refer to Draining and Filling Cooling System (L61) .
  3. Remove the hood latch. Refer to Hood Latch Replacement in Body Front End.
  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: Locating Upper Radiator Mount Bolts
    GM25877Courtesy 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 SIR Disabling and Enabling Zone 1 in SIR.
  8. Remove the cooling fan assembly. Refer to Cooling Fan Replacement - Electric .
  9. Use theJ 38185  in order to reposition the radiator outlet hose clamp from the radiator (7).
    Fig 2: View Of Surge Tank Components
    GM1172693Courtesy of GENERAL MOTORS CORP.
  10. Remove the radiator outlet hose from the radiator (6).
  11. Remove the lower transmission oil cooler line from the radiator.
    12. Fig 3: Locating Lower Transmission Oil Cooler Line
    GM12063Courtesy 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 in Body Front End.
  14. Remove the upper transmission oil cooler line from the radiator.
  15. Use the J 38185  in order to reposition the radiator inlet hose clamp from the radiator (1).
    Fig 4: View Of Surge Tank Components
    GM1172693Courtesy of GENERAL MOTORS CORP.
  16. Remove radiator inlet hose from radiator (2).
  17. Remove the surge tank inlet hose (3) and the clamp from the radiator.
    Fig 5: Identifying Radiaror Vent & Outlet Hoses
    GM1195908Courtesy of GENERAL MOTORS CORP.
  18. Remove condenser to radiator mounting bolts (2).
  19. Remove the condenser from the radiator, if equipped. The radiator can be removed without discharging the A/C System.
    Fig 6: Identifying Radiator Condenser
    GM25811Courtesy of GENERAL MOTORS CORP.
  20. Remove the radiator assembly from the vehicle.
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