Mechanics

SATURN ION RADIATOR PROBLEM

2005 Saturn Ion • 150,000 miles

How to take radiator off?
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Guest
December 16, 2012.




Drain the cooling system.
Lower the vehicle.
Remove the air cleaner outlet resonator.
Reposition the radiator inlet hose clamp at the radiator using SA9111E.
Remove the radiator inlet hose from the radiator.

Reposition the radiator outlet hose clamp at the radiator using SA9111E.
Remove the radiator outlet hose from the radiator.

If equipped with an automatic or VTi transmission, clean the upper transmission oil cooler line connection point and remove the line from the radiator.

If equipped with an automatic or VTi transmission, remove the left front wheelhouse liner.

If equipped with an automatic or VTi transmission, remove the left engine splash shield.

If equipped with an automatic or VTi transmission, clean the lower transmission oil cooler line connection point and remove the line from the radiator.

Remove the cooling fan assembly from the radiator by pushing up on the fan shroud to unsnap the retaining features. Position the cooling fan assembly away from the radiator and support the cooling fan assembly.

Remove the air dam push-in retainer.
Remove the air dam.

If equipped with air conditioning, remove the condenser bolts.

Important: You are not required to discharge the A/C System.
Slide the condenser down to disengage the upper mounting tabs from the radiator. Position the condenser away from the radiator and support the condenser.

Remove the right and left radiator side baffles.

Remove the right engine splash shield to radiator mount push-in retainer.
If equipped with a manual transmission, remove the left engine splash shield to radiator mount push-in retainer.

Remove the lower radiator mounts, brackets, and bolts.

Tilt the condenser forward in the vehicle. Tilt the cooling fan assembly rearward in the vehicle. Remove the radiator assembly from the vehicle.

Remove the upper radiator air baffle.
Installation Procedure

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

Install the upper radiator air baffle.

Tilt the condenser forward in the vehicle. Tilt the cooling fan assembly rearward in the vehicle. Install the radiator assembly into the vehicle.

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

Notice: Refer to Fastener Notice in Service Precautions.
Install the lower radiator mounts, brackets, and bolts.
Tighten the bolts to 25 Nm (18 ft. Lbs.).

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

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

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

Install the condenser bolts.
Tighten the bolts to 10 Nm (88 inch lbs.).

Install the air dam and push-in retainers.

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.

If equipped with an automatic or VTi transmission, install the lower transmission oil cooler line and seal the radiator.
Tighten the transmission oil cooler line to 20 Nm (15 ft. Lbs.).

If equipped with an automatic or VTi transmission, install the left engine splash shield.

If equipped with an automatic or VTi transmission, install the left front wheelhouse liner.
Lower the vehicle.

If equipped with an automatic or VTi transmission, install the upper transmission oil cooler line and seal to the radiator.
Tighten the transmission oil cooler line to 20 Nm (15 ft. Lbs.).

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

Install the radiator inlet hose to the radiator.
Reposition the hose clamp to secure the hose using SA9111E.
Install the air cleaner outlet resonator.
Fill the cooling system.
Important: Do not use ATF P/N 21005966 or P/N 21019223, these fluids are not compatible with these transmissions. Use Saturn P/N 22689186 for the AF 23-5 and 22688912 for the VT25-E.
If equipped with an automatic or VTi transmission, add fluid to the transmission as necessary.

ASEMaster6371
Dec 16, 2012.


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