Alero, Grand Am 1999-2005

Removal & Installation

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CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.


NOTE
When adding coolant, it is important that you use GM Goodwrench DEX-COOL- coolant. If coolant other than DEX-COOL- is added to the system, the engine coolant will require change sooner: at 30,000 miles (50, 000km) or 24 months.


WARNING
 Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

  1. Remove the battery.
  2.  
  3. Remove the battery tray.
    NOTE
    Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  4.  
  5. Recover the A/C system, as outlined in the Heating & Air Conditioning Section.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the upper radiator hose.
  10.  
  11. Remove the upper transaxle cooler line.
  12.  
  13. Remove the coolant surge tank hose.
  14.  
  15. Remove the condenser inlet fitting from the discharge hose.
  16.  
  17. Disconnect the cooling fan electrical connection.
  18.  
  19. Raise the vehicle.
  20.  
  21. Remove the lower closeout panel.
  22.  
  23. Remove the lower radiator hose from the radiator.
  24.  
  25. Remove the lower transaxle cooler line.
  26.  
  27. Remove the evaporator line from the condenser outlet.
  28.  
  29. Remove the lower radiator mounting panel.
  30.  
  31. Remove the radiator, fan and condenser as an assembly from the vehicle.
  32.  
  33. Remove the condenser from the radiator.
  34.  
  35. Remove the fan shroud from the radiator.
  36.  

To install:

  1. Install the fan shroud to the radiator.
  2.  
  3. Install the condenser to the radiator. Tighten the bolt to 44 inch lbs. (5 Nm)..
  4.  
  5. Install the radiator, fan, and condenser as an assembly to the vehicle.
  6.  
  7. Install the lower radiator mounting panel. Tighten the bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Install the condenser outlet to the evaporator line. Tighten bolt to 18 f t. lbs. (25 Nm).
  10.  
  11. Install the lower radiator hose to the radiator.
  12.  
  13. Install the lower closeout panel.
  14.  
  15. Lower the vehicle. Install the cooling fan electrical connection.
  16.  
  17. Install the lower transaxle cooler line. Tighten the bolt to 22 ft. lbs. (30 Nm).
  18.  
  19. Install the condenser inlet fitting to the discharge hose. Tighten the bolt to 18 ft. lbs. (25 Nm).
  20.  
  21. Install the coolant surge tank hose.
  22.  
  23. Install the upper transaxle cooler line. Tighten the bolt to 22 ft. lbs. (30 Nm).
  24.  
  25. Install the upper radiator hose.
  26.  
  27. Refill the cooling system.
  28.  
  29. Recharge the A/C system, as outline in the Heating & Air Conditioning Section.
  30.  
  31. Install the battery tray.
  32.  
  33. Install the battery.
  34.  
  35. Inspect the cooling system for leaks.
  36.  


NOTE
This procedure requires the use of Hose Clamp Pliers J38185 and Halogen Leak Detector J 39400-A, or their equivalents.

  1. Remove the battery.
  2.  
  3. Remove the battery tray.
    NOTE
    Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  4.  
  5. Recover the A/C system, as outlined in the Heating & Air Conditioning Section.
  6.  
  7. Drain the cooling system.
  8.  
  9. Use the Hose Clamp Pliers in order to reposition the upper radiator hose clamp.
  10.  
  11. Remove the upper radiator hose.
  12.  
  13. Remove the upper transaxle cooler line.
  14.  
  15. Use the Hose Clamp Pliers in order to reposition the surge tank hose clamp from the surge tank.
  16.  
  17. Remove the coolant surge tank hose.
  18.  
  19. Remove the condenser inlet fitting from the discharge hose.
  20.  
  21. Remove and discard the sealing washer.
    NOTE
    Cap or tape off the open A/C hose to prevent system contamination.

  22.  
  23. Disconnect the cooling fan electrical connector.
  24.  
  25. Raise the vehicle.
  26.  
  27. Remove the lower closeout panel.
  28.  
  29. Use the Hose Clamp Pliers in order to reposition the lower radiator hose clamp from the radiator.
  30.  
  31. Remove the lower radiator hose from the radiator.
  32.  
  33. Remove the lower transaxle cooler line.
  34.  
  35. Remove the evaporator line from the condenser outlet.
  36.  
  37. Remove the lower radiator mounting panel.
  38.  
  39. Remove the radiator, fan and condenser as an assembly from the vehicle.
  40.  
  41. Remove the condenser from the radiator.
  42.  
  43. Remove the fan shroud from the radiator.
  44.  

To install:

  1. Install the fan shroud to the radiator.
  2.  
  3. Install the condenser to radiator bolts and tighten to 44 inch lbs. (5 Nm).
  4.  
  5. Install the radiator, fan, and condenser as an assembly to the vehicle.
  6.  
  7. Install the lower radiator mounting panel. Tighten the bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Install the condenser outlet to the evaporator line bolt. Tighten the bolt to 18 ft. lbs. (25 Nm).
  10.  
  11. Use the Hose Clamp Pliers in order to reposition the lower radiator hose clamp to the radiator.
  12.  
  13. Install the lower radiator hose to the radiator.
  14.  
  15. Install the lower closeout panel.
  16.  
  17. Lower the vehicle.
  18.  
  19. Install the cooling fan electrical connection.
  20.  
  21. Install the lower transaxle oil cooler line. Tighten the fitting to 22 ft. lbs. (30 Nm).
  22.  
  23. Remove the cap or tape from the discharge hose.
  24.  
  25. Install a new sealing washer to the discharge hose.
  26.  
  27. Install the condenser inlet fitting to the discharge hose. Tighten the fitting to 18 ft. lbs. (25 Nm).
  28.  
  29. Install the coolant surge tank hose.
  30.  
  31. Install the upper transaxle oil cooler line fitting.
  32.  
  33. Tighten the fitting to 22 ft. lbs. (30 Nm).
  34.  
  35. Install the upper radiator hose.
  36.  
  37. Use the Hose Clamp Pliers in order to reposition the upper radiator hose clamp.
  38.  
  39. Refill the cooling system.
  40.  
  41. Recharge the A/C system, as outline in the Heating & Air Conditioning Section.
  42.  
  43. Leak test the fittings of the reinstalled components using the Halogen Leak Detector.
  44.  
  45. Install the battery tray.
  46.  
  47. Install the battery.
  48.  

 
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