Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Radiator Replacement (LUV)

Removal Procedure
  1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  2. Remove the front compartment front insulator cover. Refer to Front Compartment Front Insulator Cover Replacement.
  3. Remove the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement
  4. If equipped with an automatic transmission remove the transmission cooler lines. Refer to Fluid Cooler Inlet Hose Replacement and Fluid Cooler Outlet Hose Replacement.
  5. Drain the engine coolant. Refer to Cooling System Draining and Filling.
  6. Remove the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement.
  7. Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement
  8. Remove the front bumper fascia assembly. Refer to Front Bumper Fascia Replacement.
  9. Remove the radiator upper air baffle. Refer to Radiator Air Baffle Replacement


  10. Remove the three air conditioning condenser bracket fasteners (1) and bracket. (2).
  11. Release the clips securing the air conditioning condenser (1) to the radiator and pull the condenser (1) forward as far as possible.
  12. Support the air conditioning condenser assembly.

  13. Remove the radiator upper bracket fasteners (1) and brackets (2).

  14. Remove the radiator assembly from the vehicle.

  15. Remove the following components from the radiator assembly (1).
  • Radiator upper insulators (2)  (Qty:2)
  • Radiator lower insulators (3)  (Qty: 2)
  • Radiator temperature sensor (5) and retainer clip (4)
Installation Procedure

    Install the following components to the radiator assembly (1).
  1. Install the following components to the radiator assembly (1).
  • Radiator upper insulators (2)  (Qty:2)
  • Radiator lower insulators (3)  (Qty: 2)
  • Radiator temperature sensor (5) and retainer clip (4)
Install the radiator assembly into the vehicle.
  • Install the radiator assembly into the vehicle.

  • Caution:

    Refer to Fastener Caution.

  • Install the radiator upper brackets (2) and bracket  fasteners (1) tighten the bracket fasteners to 9Y(80 lb in)

    .



  • Position the air conditioning condenser (1) to the radiator, and push inward securing the air conditioning condenser to the radiator assembly.
  • Install the air conditioning condenser bracket (2) and the air conditioning condenser fasteners (1) .
  • Install the radiator upper air baffle. Refer to Radiator Air Baffle Replacement
  • Install the front bumper fascia assembly. Refer to Front Bumper Fascia Replacement.
  • Install the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement
  • Install the radiator inlet hose from the radiator. Refer to Radiator Inlet Hose Replacement.
  • If equipped with an automatic transmission install the transmission cooler lines. Refer to Fluid Cooler Inlet Hose Replacement and Fluid Cooler Outlet Hose Replacement.
  • Install the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement
  • Install the front compartment front insulator cover. Refer to Front Compartment Front Insulator Cover Replacement.
  • Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  • Radiator Replacement (LDE LUW)
    Radiator Replacement Callout Component Name Preliminary Procedures Drain the coolant. Refer to Cooling System Draining and Filling. ...

    Radiator Surge Tank Outlet Hose Replacement (LDE LUW)
    Radiator Surge Tank Outlet Hose Replacement Callout Component Name Preliminary Procedure Drain the coolant. Refer to Cooling Sy ...

    Other materials:

    License Plate Lamp
    Lamp Assembly Bulb Assembly Bulb Socket Bulb Lamp Assembly To replace one of these bulbs: Push the left end of the lamp assembly toward the right. Turn the lamp assembly down to remove it. Turn the bulb socket (1) counterc ...

    Front Side Door Replacement
    Front Side Door Replacement Callout Component Name Warning: Refer to SIR Warning. Preliminary Procedures Mark the location of the hinge before removing the bolts with a grease pencil. Remove the front door ...

    Intake Manifold Installation (1.6L LDE)
    Clean the sealing surfaces. Insert the NEW gasket. Caution: Refer to Fastener Caution. Install the intake manifold (2) and the 7 intake manifold bolts (1) and tighten to  20 Y (15 lb ft). Install the intake manifold supp ...

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