Catera 2000-2001

Removal & Installation

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NOTE
This procedure requires the use of s cooling fan temperature switch socket, special tool J42865 or equivalent.


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.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the upper radiator covers:
    1. Release the self-locking tabs.
    2.  
    3. Remove the upper radiator cover screws and remove the upper radiator cover.
    4.  

  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the intake air resonator.
  10.  
  11. Remove the cooling fan shroud.
  12.  
  13. Disconnect the cooling fan control switches electrical connectors.
  14.  
  15. Remove the surge tank hose from the radiator.
  16.  
  17. Remove the coolant hose from the secondary auxiliary coolant pump.
  18.  
  19. Remove the condenser-to-radiator bracket bolts (1).

    Click image to see an enlarged view

    Fig. Condenser/radiator mounting bracket bolts (1)

  20.  
  21. Remove the radiator inlet hose clamp from the radiator.
  22.  
  23. Remove the radiator inlet hose from the radiator.
  24.  
  25. Remove the radiator outlet hose clamp from the radiator.
  26.  
  27. Remove the radiator outlet hose from the radiator.
  28.  
  29. Remove the transmission oil cooler to radiator top bolts.
  30.  
  31. Disconnect the secondary auxiliary coolant pump connector.
  32.  
  33. Remove the upper radiator upper mounting retainers.
  34.  
  35. Lift and rock the radiator to unseat lower retainers.
  36.  
  37. Remove the radiator (2) and the transmission oil cooler together from the radiator support.
  38.  
  39. Remove the transmission oil cooler bolts.
  40.  
  41. Remove the transmission oil cooler from the radiator.
  42.  
  43. Use the J42865 or equivalent to remove the cooling fan control switches, if necessary.
  44.  

To install:

  1. Use the J42865 or equivalent to install the cooling fan control switches, if removed and tighten to 16 ft. lbs. (22 Nm).
  2.  
  3. Install the transmission oil cooler to the radiator.
  4.  
  5. Install the radiator (2) and the transmission oil cooler together to the radiator support:
  6.  
  7. Engage the tabs on the bottom of the radiator in the lower retainers.
  8.  
  9. Engage the upper retainers in the radiator support brackets.
  10.  
  11. Connect the secondary auxiliary coolant pump electrical connector.
  12.  
  13. Install the transmission oil cooler to radiator top bolts and tighten to 89 inch lbs. (10 Nm).
  14.  
  15. Install the radiator outlet hose to the radiator.
  16.  
  17. Install the radiator outlet hose clamp to the radiator.
  18.  
  19. Install the radiator inlet hose to the radiator.
  20.  
  21. Install the radiator inlet hose clamp to the radiator.
  22.  
  23. Install the condenser-to-radiator bracket bolts (1) and tighten to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Condenser/radiator mounting bracket bolts (1)

  24.  
  25. Connect the surge tank hose to the radiator.
  26.  
  27. Connect the cooling fan control switches electrical connectors.
  28.  
  29. Install the cooling fan shroud.
  30.  
  31. Install the intake air resonator.
  32.  
  33. Install the upper radiator covers:
    1. Position the upper radiator covers.
    2.  
    3. Install the upper radiator cover screws.
    4.  

  34.  
  35. Insert the self-locking tabs.
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Fill the cooling system.
  40.  

 
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