Installation Procedure

WARNING: This page is about a different car, the 2007 Saturn Ion Red Line, 2007 Saturn Ion 3, and 2007 Saturn Ion 2. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Locating Upper Radiator Mounts

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Verify that the upper radiator mounts are installed in the vehicle.

Fig 2: View Of Upper Radiator Air Baffle

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Install the upper radiator air baffle.

Fig 3: Tilting Condenser

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Tilt the condenser forward in the vehicle. Install the radiator assembly into the vehicle.

Fig 4: Aligning Upper Radiator Mount Pins With Upper Radiator Mounts

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Verify that the upper radiator mount pins align with the upper radiator mounts.

Fig 5: View Of Lower Radiator Mount, Brackets And Bolts

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NOTE: Refer to Fastener Notice .

Install the lower radiator mounts, brackets, and bolts.
Tighten: Tighten the bolts to 25 N.m (18 lb ft).

Fig 6: View Of Left Engine Splash Shield-To-Radiator Mount Push-In Retainer

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Install the right engine splash shield to radiator mount push-in retainer.
If equipped with a manual transaxle, install the left engine splash shield to radiator mount push-in retainer.

Fig 7: View Of Right & Left Radiator Side Baffles

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If equipped with air conditioning, install the right and left radiator side baffles.

Fig 8: Locating Radiator Upper Mounting Tabs

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Slide the condenser up to engage the upper mounting tabs into the radiator.

Fig 9: Locating Condenser Bolts

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

Fig 10: View Of Air Dam And Push-In Retainers

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Install the air dam and push-in retainers.

Fig 11: View Of Cooling Fan Assembly-To-Radiator Connectors

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Align the cooling fan shroud retaining features to the radiator. Pull down on the cooling fan assembly to snap the fan shroud onto the radiator.

Fig 12: View Of Lower Transmission Oil Cooler Line

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If equipped with an automatic transaxle, install the lower transmission oil cooler line and seal the radiator.
Tighten: Tighten the transmission oil cooler line to 20 N.m (15 lb ft).
Lower the vehicle.

Fig 13: View Of Upper Transmission Oil Cooler Line

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If equipped with an automatic transaxle, install the upper transmission oil cooler line and seal to the radiator.
Tighten: Tighten the transmission oil cooler line to 20 N.m (15 lb ft).

Fig 14: View Of Radiator Outlet Hose & Radiator - 2.2L

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Install the radiator outlet hose to the radiator.
Reposition the hose clamp to secure the hose using SA9111E . See Special Tools .

Fig 15: View Of Radiator Inlet Hose & Radiator - 2.2L

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Install the radiator inlet hose to the radiator.
Reposition the hose clamp to secure the hose using SA9111E . See Special Tools .
Install the charge air cooler, if equipped. Refer to Radiator Replacement - Charge Air Cooler .
Install the air cleaner duct. Refer to the appropriate procedure:
- Air Cleaner Inlet Duct Replacement for the 2.0L engine
- Air Cleaner Inlet Duct Replacement for the 2.2L engine
- Air Cleaner Outlet Duct Replacement for the 2.4L engine
Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ) Static Fill) or Draining and Filling Cooling System (2.2L (L61), 2.4L (LE5) Static Fill) or Draining and Filling Cooling System (GE 47716 Fill) .
If equipped with an automatic transaxle, add fluid to the transmission as necessary. Refer to Transmission Fluid Checking .