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Home >> Saturn >> 2009 >> Astra XR, 2D Hatchback, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Cooling System (Mechanical) >> Engine Cooling >> Repair Instructions >> Radiator Replacement >> Installation Procedure

Installation Procedure

  1. Install the attaching parts to the radiator.
    • Install the 2 rubber bushes.
    • Push on the 6 sheet metal nuts.
    • Install the coolant temperature sensor.
  2. Insert the radiator from below.

    Secure to the upper radiator with a suitable tool.

    3. CAUTION: Refer to Fastener Caution .
    NOTE: Arrow on bracket points to the front of the vehicle.
  3. Install the lower radiator bracket.

    Tighten:  Tighten the 4 bolts to 15 N.m (11 lb ft).

  4. Remove the fuses.
  5. Lower the vehicle by half its height.
  6. Install the condenser to the radiator.

    Tighten:  Tighten the 4 bolts to 5 N.m (44 lb in).

  7. Remove the retaining straps.
  8. Lower the vehicle by half its height.
  9. Install the fan housing.
    • Insert in bracket at the bottom of the radiator.

      Tighten:  Tighten the 2 bolts to 5 N.m (44 lb in).

    • Install the 2 radiator hoses into the bracket.
    • Install the NEW cable tie.
  10. Install the expansion tank coolant hose to the radiator.
    • Fasten the clamp.
    • Install the coolant hose.
  11. Raise the vehicle by its full height.
  12. Install the lower oil cooling line with the connecting hose on the oil cooler.

    Use NEW seal rings.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

  13. Install the upper oil cooling line with the connecting hose on the oil cooler.

    Use NEW seal rings.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

  14. Install the 2 coolant hoses to the radiator.

    Install the 2 clamps.

  15. Connect the fan wiring harness plug.
  16. Lower the vehicle by half its height.
  17. Install the front fascia.
    • Connect the 2 wiring harness plugs.
    • Install the front fascia on the side.
  18. Install the front paneling at bottom.

    Install the 6 body-bound rivets.

    Tighten:  Tighten the 4 bolts to 2.5 N.m (22 lb in).

  19. Lower the vehicle by half its height.
  20. Install the fascia at top.

    Fasten the 2 body-bound rivets.

    Tighten:  Tighten the 2 bolts to 2.5 N.m (22 lb in).

  21. Install the radiator grille.
    • Install the 6x.
    • Install the 4 body-bound rivets.
  22. Fill and bleed the cooling system. Refer to Cooling System Draining and Filling .
  23. Connect the battery.

    Connect the negative connection.

    Tighten:  Tighten the nut to 5 N.m (44 lb in).

  24. For reprogramming procedures, refer to Control Module References .
  25. Close the hood.
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