GM Corvette 1984-1996 Repair Guide

Radiator

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REMOVAL & INSTALLATION




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.

5.7L (VIN 8) Engines
1984-88 vehicles

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Unfasten the hose clamp, then disconnect the upper radiator hose.
  6.  
  7. Remove the lower radiator hose.
  8.  
  9. Disconnect the overflow hose from the radiator.
  10.  
  11. Unbolt the A/C accumulator and position it aside, out of the way.
  12.  
  13. If equipped with an automatic transmission, disconnect and plug the transmission cooler line.
  14.  
  15. Detach the fan wiring from the fan and shroud.
  16.  
  17. Remove the fan in order to gain access to the lower cooler line.
  18.  
  19. If equipped with an automatic transmission, unfasten the transmission cooler line at the fitting, then plug the line.
  20.  
  21. Remove the upper shroud mounting bolts, then remove the upper shroud.
  22.  
  23. Carefully remove the radiator from the vehicle.
  24.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the radiator mounting-1984-88 vehicles

To install:
  1. Position the radiator on the lower support.
  2.  
  3. If equipped, unplug, then connect the lower transmission cooler line.
  4.  
  5. Install the upper shroud and secure with the mounting bolts.
  6.  
  7. Install the fan and connect the wiring.
  8.  
  9. If equipped, unplug and connect the upper transmission cooler line.
  10.  
  11. Connect the upper and lower radiator hose. Secure with the hose clamps, if applicable.
  12.  
  13. Attach the overflow hose.
  14.  
  15. Place the A/C accumulator in position and secure with the mounting bolts.
  16.  
  17. Fill the radiator with the proper type and amount of coolant.
  18.  
  19. Start the engine, and allow to run (with the radiator cap still removed), until the upper hose is hot (thermostat is open). With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck.
  20.  
  21. Install the filler cap. Inspect for leaks. Turn the engine OFF .
  22.  

1989-91 vehicles
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the radiator cap, then drain the cooling system into a suitable container.
  4.  
  5. Remove the air cleaner and intake duct assembly.
  6.  
  7. Detach the Mass Air Flow (MAF) sensor electrical connector.
  8.  
  9. Unfasten the upper and lower hose clamp, then disconnect the hoses.
  10.  
  11. Disconnect the overflow hose from the radiator.
  12.  
  13. Remove the engine cooling fan upper screws from the shroud.
  14.  
  15. Unbolt the A/C accumulator bracket from the shroud and position aside.
  16.  
  17. If equipped with an automatic transmission, disconnect and plug the oil cooler line.
  18.  
  19. Remove the wire harness and relay from the shroud.
  20.  
  21. Unfasten the power steering reservoir bracket bolts from the shroud and frame.
  22.  
  23. Remove the shroud retaining screws, then remove the shroud.
  24.  
  25. Carefully remove the radiator from the vehicle.
  26.  

To install:
  1. Position the radiator into the vehicle.
  2.  
  3. Install the shroud and secure with the retaining screws.
  4.  
  5. Fasten the power steering reservoir bracket bolts at the shroud and frame.
  6.  
  7. Install the wire harness and relay onto the shroud.
  8.  
  9. Unplug and connect the automatic transmission oil cooler line. Tighten the fittings to 20 ft. lbs. (27 Nm).
  10.  
  11. Position the A/C accumulator bracket on the shroud, then install the retainers.
  12.  
  13. Install the cooling fan screws on the shroud.
  14.  
  15. Connect the overflow hose to the radiator.
  16.  
  17. Install the lower and upper radiator hose and secure with the clamps.
  18.  
  19. Install the air cleaner and intake duct assembly.
  20.  
  21. Connect the MAF sensor electrical connector.
  22.  
  23. Fill the radiator with the proper type and amount of coolant.
  24.  
  25. Start the engine, and allow to run (with the radiator cap still removed), until the upper hose is hot (thermostat is open). With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck.
  26.  
  27. Install the filler cap. Inspect for leaks. Turn the engine OFF .
  28.  

5.7L (VIN J, P and 5) Engines

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the surge tank/radiator pressure cap. Drain the engine coolant into a suitable container.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Remove the radiator upper deflector/shroud.
  8.  
  9. Detach the electrical connectors from the cooling fan relays.
  10.  
  11. Unfasten the bolts securing the A/C accumulator bracket to the radiator upper support, and position the bracket aside.
  12.  
  13. Remove the fan shroud-to-upper support retaining screws.
  14.  
  15. If equipped, remove the rubber access plug from the top of the radiator.
  16.  
  17. Unfasten the radiator air bleed/overflow hose clamp, then disconnect the hose.
  18.  
  19. Remove the nuts and bolt holding the upper support to the front side member.
  20.  
  21. Unfasten the bolts securing the oil cooler lines to the cooler.
  22.  
  23. Remove the seal retainers and seal from the oil cooler and A/C line.
  24.  
  25. If necessary, detach the electrical connection from the AIR pump and horn.
  26.  
  27. Remove the AIR pump.
  28.  
  29. Remove the bolt retaining the AIR pump bracket at the rear and loosen the front bolt.
  30.  
  31. Remove the air pump intake duct.
  32.  
  33. Unfasten the screws retaining the upper support to the lower support, then remove the upper support from the vehicle.
  34.  



Click image to see an enlarged view

Fig. Fig. 2: You must remove the upper support for access to the radiator-5.7L (VIN J, P and 5) engines

  1. Loosen the radiator inlet and outlet hose clamps, then disconnect the hoses.
  2.  
  3. Carefully remove the radiator from the vehicle.
  4.  

To install:
  1. Position the radiator in the vehicle.
  2.  
  3. Attach the inlet and outlet hoses and secure with the retaining clamps.
  4.  
  5. Install the upper support and secure with the retaining screws.
  6.  
  7. Instal the nuts and bolts retaining the upper support to the front side member and tighten to 18 ft. lbs. (25 Nm).
  8.  
  9. Install the AIR pump intake duct. Install the bolts retaining the AIR pump bracket, then install the pump. Attach the electrical connectors to the AIR pump and horn, if necessary.
  10.  
  11. Attach the electrical connectors to the cooling fan relays.
  12.  
  13. Install the fan shroud-to-upper support screws and tighten to 80 inch lbs. (9 Nm).
  14.  
  15. Fasten the bolts securing the accumulator bracket to the upper support. Tighten to 80 inch lbs. (9 Nm).
  16.  
  17. Install the retainers to the oil cooler/A/C line seal.
  18.  
  19. Fasten the bolts retaining the oil cooler lines to the cooler and tighten to 89 inch lbs. (10 Nm).
  20.  
  21. Attach the air bleed hose/overflow hose and secure with the retaining clamp.
  22.  
  23. Install the access plug.
  24.  
  25. Attach the upper air deflector.
  26.  
  27. Install the air cleaner assembly.
  28.  
  29. Fill the radiator with the proper type and amount of coolant.
  30.  
  31. Start the engine, and allow to run (with the radiator cap still removed), until the upper hose is hot (thermostat is open). With the engine idling, add coolant to the radiator until it reaches the bottom of the filler neck.
  32.  
  33. Install the filler cap. Inspect for leaks. Turn the engine OFF .
  34.  

 
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