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Home >> Pontiac >> 2004 >> Aztek Base, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 213 (Engine Cooling System) >> Repair Instructions >> Radiator Replacement >> Installation Procedure
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Installation Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Monte Carlo and 2004 Chevrolet Impala. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the radiator to the lower mounts.
    2. Fig 1: Removing/Installing Radiator Hoses To/From Radiator
    GM455227Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Verify that the condenser is fully seated in the radiator mounting tabs.
  2. Install the condenser to the mounting tabs on the radiator (2).
  3. Install the condenser hold down bracket (1) to the radiator and condenser.
    4. Fig 2: Condenser Hold Down Bracket & Mount Tabs
    GM1202952Courtesy of GENERAL MOTORS CORP.
  4. Install the air deflectors to the top of the radiator.
  5. Install the outlet hose to the radiator.
  6. Use J 38185  to install the outlet hose clamp to the radiator. See Special Tools and Equipment .
  7. Connect the transaxle oil cooler pipes to the radiator. Refer to Transmission Fluid Cooler Line Quick Connect Fitting in Automatic Transaxle - 4T65 - E.
    8. NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the bolt for the condenser tube support bracket to the radiator.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    9. IMPORTANT: Ensure the lower edge of the fan shroud engages the clip at the bottom of the radiator.
  9. Install the cooling fan shroud.
    10. Fig 3: Removing/Installing Cooling Fan Shroud
    GM1202851Courtesy of GENERAL MOTORS CORP.
  10. Install the cooling fan motors electrical harness to the fan shroud clips.
  11. Connect the engine cooling fan motors electrical connector.
  12. Install the cooling fan shroud bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

  13. Install the radiator upper support brackets and bolts that connect to the fan shroud.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    14. Fig 4: View Of Fan Shroud To Radiator Upper Support Brackets
    GM1202856Courtesy of GENERAL MOTORS CORP.
  14. Install the bolt that connects the fan shroud to the condenser hold down bracket.

    Tighten:  Tighten the bolt to 6 N.m (53 lb in).

    15. Fig 5: Identifying Fan Shroud To Condenser Hold Down Bracket Bolt
    GM1202860Courtesy of GENERAL MOTORS CORP.
  15. Install the inlet hose to the radiator.
  16. Use J 38185  to install the inlet hose clamp to the radiator. See Special Tools and Equipment .
  17. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-3.8L or Air Cleaner Assembly Replacement in Engine Controls-3.4L.
  18. Install the coolant reservoir hose to the radiator overflow neck.
  19. Install the right and left engine mount struts. Refer to the following procedures:
  20. Install the transmission oil cooler lines to the retainer clip at the bottom of the cooling fan shroud.
  21. Fill the cooling system. Refer to Draining and Filling Cooling System .
  22. Install the battery. Refer to Battery Replacement in Engine Electrical.
    23. NOTE: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle.
  23. Adjust the transaxle fluid level.
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