How to Change a Radiator on a Saturn

The radiator on a Saturn is comprised of a series of long tubes running from left to right with a tank on each side. Engine coolant is pumped from the engine to the radiator through the upper radiator hose. Coolant flows down through the radiator; a fan draws cool air in from the vehicle's grill and across the radiator. This air draws heat off the engine coolant. The coolant then returns to the engine through the lower radiator hose.

Instructions

Disconnect the ground cable from the negative battery terminal. Use a wrench to loosen the retaining bolt, and then pull the clamp off the terminal.

Drain the radiator. Locate the petcock valve on the lower right corner of the radiator. Place a waste oil collection pan underneath it. Use needle-nose pliers to turn the valve counterclockwise.

Loosen the hose clamps on either end of the air intake duct, using a Phillips screwdriver.

Pull the wiring connector off the air temperature sensor. The air temperature sensor is located in the air intake duct.

Remove the air intake duct from the vehicle.

Use locking pliers to loosen the hose clamp that connects the upper radiator hose to the radiator. Slide the clamp back away from the radiator.

Pull the upper radiator hose off the radiator.

Unscrew the transmission cooler lines from the radiator (vehicles with automatic transmission only). Using a wrench, unscrew the fitting that secures the transmission line to the radiator.

Plug the transmission line to prevent transmission fluid from leaking out.

Disconnect the wiring harness from the electric fan assembly by pulling the plastic wiring connectors off the assembly.

Use a socket to remove the screws that connect the engine fan to the radiator..

Lift the engine fan straight up and remove it from the vehicle.

Use locking pliers to loosen the hose clamp that secures the lower radiator hose to the radiator. Slide the clamp away from the radiator.

Pull the lower radiator hose off the radiator.

Raise the front of the vehicle using an automotive jack and support with jack stands.

Use a socket to remove the four bolts that secure the splash shield on the bottom of the vehicle just below the radiator. Remove the splash shield from the vehicle.

Use a socket to remove the two bolts on either side that connect the A/C condenser to the radiator.

Unscrew the upper radiator mounting nuts and remove the brackets from the vehicle, using a socket. They will be located on top of the radiator at each corner.

Carefully lift the radiator up and out of the engine bay. Remove it from the vehicle.

Carefully lower the radiator into position at the core support.

Reinstall the upper radiator mounting nuts and brackets at the top corners of the radiator, using a socket.

Use a socket to screw in the two bolts on each side of the radiator that secure the A/C condenser to the radiator.

Lift the splash shield into position under the radiator. Screw in the four bolts that retain it, using a socket.

Lower the vehicle.

Push the lower radiator hose onto the fitting at the bottom of the radiator.

Loosen the hose clamp on the lower radiator hose, using a pair of locking pliers. Slide the clamp over the fitting on the radiator.

Lower the engine fan assembly into position next to the radiator.

Screw in the screws that connect the engine fan to the radiator, using a socket.

Press the wiring connector onto the back of the engine fan, using your hand.

Reconnect the transmission cooler lines to the radiator. Pull the plugs out of the lines and thread the fitting into the radiator. Tighten with a wrench.

Push the upper radiator hose onto the fitting at the top of the radiator.

Loosen the hose clamp on the upper radiator hose with locking pliers. Slide the clamp over the fitting on the radiator.

Lower the air intake duct into position.

Reinstall the clamps that secure the air intake duct, using a Phillips screwdriver.

Press the wiring connector onto the air temperature sensor.

Check that the petcock valve on the side of the radiator is closed. Fill the radiator with a 50/50 mix of fresh antifreeze and water.

Remove the radiator cap from the old radiator and install it in the new one.

Connect the ground cable to the negative battery terminal. Slide the clamp over the terminal. Use a wrench to tighten the retaining bolt.

Run the engine and visually inspect for leaks.