G6 2005-2007

Removal & Installation

Print

2.4L Engine



  1. Remove the cooling fan and shroud assembly.
  2.  
  3. Remove and discard the condenser mounting bolts.
  4.  
  5. Push upward on the condenser and downward on the radiator to unsnap the condenser mounting tabs from the radiator clips.
  6.  
  7. Remove and discard the condenser mounting nuts from the radiator.
  8.  
  9. Remove the radiator from the vehicle.
  10.  

To Install:

  1. Install the radiator to the vehicle.
  2.  
  3. Push upward on the radiator and downward on the condenser to snap the condenser mounting tabs into the radiator clips.
  4.  
  5. Install new condenser mounting nut to the radiator and tighten to 53 inch lbs. (6 Nm).
  6.  
  7. Install new condenser mounting bolts to the radiator and tighten to 53 inch lbs. (6 Nm).
  8.  
  9. Install the cooling fan and shroud assembly.
  10.  

3.5L & 3.9L Engines



  1. Drain the coolant.
  2.  
  3. Remove the headlamps.
  4.  
  5. Loop a rope around each of the upper 2 tabs of the condenser and tie the rope around the upper tie bar.
  6.  
  7. Remove the upper radiator support bracket bolts.
  8.  
  9. Remove the upper radiator support brackets.
  10.  
  11. Reposition the surge tank outlet hose clamp at the radiator.
  12.  
  13. Remove the surge tank outlet hose from the radiator.
  14.  
  15. Raise the vehicle.
  16.  
  17. Remove the lower radiator air deflector retainers.
  18.  
  19. Remove the lower radiator air deflector.
  20.  
  21. Remove the right front fender liner.
  22.  
  23. Remove the right radiator air deflector retainers.
  24.  
  25. Remove the right radiator air deflector.
  26.  
  27. Remove the left radiator air deflector retainers.
  28.  
  29. Remove the left radiator air deflector.
  30.  
  31. Remove the radiator outlet hose from the radiator.
  32.  
  33. Place a drain pan under the transmission oil cooler pipes.
  34.  
  35. Remove the transmission oil cooler pipe attachment nut from the transmission.
  36.  
  37. Remove the transmission oil cooler pipes from the transmission.
  38.  
  39. Remove the lower radiator support bracket bolts.
  40.  
  41. Remove the lower radiator support brackets.
  42.  
  43. Remove the radiator lower mounts.
  44.  
  45. Remove and discard the condenser mounting bolts from the radiator.
  46.  
  47. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
  48.  
  49. Remove and discard the condenser mounting nuts from the radiator.
  50.  
  51. Remove the radiator air side seals.
  52.  
  53. Remove the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
  54.  
  55. Remove the transmission oil cooler pipes from the radiator.
  56.  
  57. Pry upward on the fan shroud tabs at the radiator clips.
  58.  
  59. Remove the cooling fan and shroud assembly.
  60.  

To Install:

  1. Install the cooling fan and shroud assembly to the radiator.
  2.  
  3. Snap the fan shroud tabs into the radiator clips.
  4.  
  5. Install the transmission oil cooler pipes to the radiator.
  6.  
  7. Install the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
  8.  
  9. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
    NOTE
    The bolt retaining the condenser to the radiator end tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.

  10.  
  11. Install the condenser mounting nuts to the radiator.
  12.  
  13. Insert the condenser mounting tabs into the radiator clips.
  14.  
  15. Install the condenser to the radiator bolts and tighten to 53 inch lbs. (6 nm).
  16.  
  17. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
  18.  
  19. The radiator air side seals must be in the proper position for proper air flow.
    NOTE
    Replace the radiator lower mounts as a pair or vibration may result.

  20.  
  21. Install the radiator lower mounts.
  22.  
  23. Install the lower radiator support brackets.
  24.  
  25. Install the lower radiator support bracket bolts and tighten to 44 ft. lbs. ( 60 Nm).
  26.  
  27. Install the transmission oil cooler pipes to the transmission.
  28.  
  29. Install the transmission oil cooler pipes attachment nut to the transmission.
  30.  
  31. Install the radiator outlet hose to the radiator.
  32.  
  33. Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.
  34.  
  35. Install the left radiator air deflector.
  36.  
  37. Install the left radiator air deflector retainers.
  38.  
  39. Install the right radiator air deflector.
  40.  
  41. Install the right radiator air deflector retainers.
  42.  
  43. Install the right front fender liner.
  44.  
  45. Install the lower radiator air deflector.
  46.  
  47. Install the lower radiator air deflector retainers.
  48.  
  49. Lower the vehicle.
  50.  
  51. Install the radiator inlet hose to the radiator.
  52.  
  53. Install the surge tank outlet hose to the radiator.
  54.  
  55. Reposition the surge tank outlet hose clamp at the radiator.
  56.  
  57. Remove the rope attached to the condenser and upper tie bar.
  58.  
  59. Install the upper radiator support brackets.
  60.  
  61. Install the upper radiator support bracket bolts and tighten to 89 inch lbs. (10 Nm).
  62.  
  63. Install the headlamps.
  64.  
  65. Fill the coolant.
  66.  
  67. Inspect the transmission fluid level.
  68.  

3.6L Engine



  1. Drain the coolant.
  2.  
  3. Loop a rope around each of the upper 2 tabs of the condenser and tie the rope around the upper tie bar.
  4.  
  5. Remove the upper radiator support brackets.
  6.  
  7. Reposition the radiator inlet hose clamp at the radiator.
  8.  
  9. Remove the radiator inlet hose from the radiator.
  10.  
  11. Remove the front air dam.

    Click image to see an enlarged view

    Fig. Front air dam removal shown

  12.  
  13. Remove the right engine splash shield retainers.

    Click image to see an enlarged view

    Fig. Right splash shield and retainers

  14.  
  15. Remove the right engine splash shield.
  16.  
  17. Remove the left engine splash shield retainers.
  18.  
  19. Remove the left engine splash shield.
  20.  
  21. Reposition the radiator outlet hose clamp at the radiator.
  22.  
  23. Remove the radiator outlet hose from the radiator.
  24.  
  25. Remove the transmission oil cooler pipes from the radiator.
  26.  
  27. Remove the lower radiator support bracket bolts.
  28.  
  29. Remove the lower radiator support brackets.

    Click image to see an enlarged view

    Fig. Lower radiator support bracket and bolts

  30.  
  31. Remove the radiator lower mounts.
  32.  
  33. Remove and discard the condenser mounting bolts from the radiator.
  34.  
  35. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
  36.  
  37. Remove and discard the condenser mounting nuts from the radiator.
  38.  
  39. Remove the radiator air side seals.
  40.  
  41. Remove the radiator and cooling fan shroud assembly from the vehicle.

    Click image to see an enlarged view

    Fig. Radiator and cooling fan shroud assembly removal

  42.  
  43. Pry upward on the fan shroud tabs at the radiator clips.
  44.  
  45. Remove the cooling fan and shroud assembly from the radiator.
  46.  

To Install:

  1. Install the cooling fan and shroud assembly to the radiator.
  2.  
  3. Snap the fan shroud tabs into the radiator clips.
  4.  
  5. Install the radiator and cooling fan shroud assembly to the vehicle.
  6.  
  7. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
    NOTE
    The bolt retaining the condenser to the radiator end tank is a special length and should be the only bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.

  8.  
  9. Install the condenser mounting nuts to the radiator.
  10.  
  11. Insert the condenser mounting tabs into the radiator clips.
  12.  
  13. Install the condenser to the radiator bolts and tighten to 53 inch. lbs. (63 Nm).
  14.  
  15. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
    NOTE
    The radiator air side seals must be in the proper position for proper air flow.

  16.  
  17. Install the radiator lower mounts.
    WARNING
    If replacing the radiator lower mount replace as a pair or vibration may result.

  18.  
  19. Install the lower radiator support brackets.
  20.  
  21. Install the lower radiator support bracket bolts and tighten to 44 ft. lbs. (60 Nm).
  22.  
  23. Install the transmission oil cooler pipes to the radiator.
  24.  
  25. Install the radiator outlet hose to the radiator.
  26.  
  27. Reposition the radiator outlet hose clamp at the radiator.
    WARNING
    Engine splash shields must be properly installed or reduced A/C and engine cooling system performance could occur.

  28.  
  29. Install the left engine splash shield.
  30.  
  31. Install the left engine splash shield retainers.
  32.  
  33. Install the right engine splash shield.
  34.  
  35. Install the right engine splash shield retainers.
  36.  
  37. Install the front air dam.
  38.  
  39. Lower the vehicle.
  40.  
  41. Install the radiator inlet hose to the radiator.
  42.  
  43. Reposition the radiator inlet hose clamp at the radiator.
  44.  
  45. Remove the rope attached to the condenser and upper tie bar
  46.  
  47. Install the upper radiator support brackets.
  48.  
  49. Fill and bleed cooling system.
  50.  
  51. Inspect the transmission fluid level and add if needed.
  52.  
  53. Check all connections for leaks.
  54.  

 
label.common.footer.alt.autozoneLogo